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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
DOE OSTI2025

Stokes-dependent droplet collection efficiency on a NACA 0012 airfoil from droplet-informed simulations with statistical overloading

Accurate modelling of ice accretion on aircraft wings requires analysing droplet impingement on the surface to optimize the design of ice-protection systems. We perform Euler–Lagrange simulations of a droplet-laden flow impinging on a NACA 0012 airfoil. Our study includes water droplets with eight discrete sizes ranging from 1 to 160 microns. We vary the free-stream velocity of the incoming airflow in the range 60 ≤ U ≤ 240 m s −1 and the chord length of the airfoil in the range 0.5 ≤ c ≤ 2 m. Due to the dilute nature of supercooled clouds, one-way coupling is used in the simulations. The effects of droplet breakup and collision are also neglected. To reduce the computational cost, we employ statistical overloading of droplets, allowing us to simulate millions of impinging droplets in a time span on the order of milliseconds. Our results show that the droplet collection efficiency, which measures the likelihood of droplet impingement on the airfoil surface, increases with droplet size and free-stream velocity but decreases with airfoil size. We demonstrate that collection efficiency, impingement velocity and impingement angle are primarily dictated by a single non-dimensional parameter, the droplet Stokes number. We also identify a critical stagnation-streamline Stokes number below which impingements do not occur and use it to estimate the minimum droplet size for impingement. In addition, we observe droplet behaviour to become Stokes number independent at large values of the Stokes number. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.

Science & Technology - Other Topics↗
DOE OSTI2023

Integration of a transonic high-pressure turbine with a rotating detonation combustor and a diffuser

Abstract In this paper, a diffuser is used to integrate a transonic high-pressure turbine with a rotating detonation combustor (RDC). The paper focuses on the required design modifications to the turbine endwalls (EW) to enable high efficiency, while preserving the airfoil blade-to-blade geometry. The main challenge is the stator passage unstarting, due to the high inlet Mach number. First of all, steady Reynolds Averaged Navier Stokes simulations were performed to compare the efficiency of turbines with constant-radius EWs to turbines with axisymmetric EWs. A modified EW design prevented the unstarting of the stator passage, enabling a significant gain in performance. Afterward, the influence on the turbine efficiency and damping due to the unsteadiness from the diffuser-like fluctuations of the RDC was evaluated with unsteady Reynolds Averaged Navier Stokes simulations with a mixing plane approach (MPA). Full unsteady simulations were carried out on selected inlet conditions and compared to the mixing plane results. This parametric study provides turbine designers with recommended diffusion rates along the vane EWs. Additionally, we provide guidance on the upstream diffuser design, specifically the required damping and outlet Mach number.

Engineering↗
DOE OSTI2024

AI Design Assistant

SAND2025-01930O The AI Design Assistant uses ChatGPT to provide a natural language interface to airfoil analysis tools (XFOIL). Most of the code base is glue code, connecting XFOIL (a tool for analyzing airfoils) to the OpenAI interface. Among the more novel features are an airfoil geometry class and methods on how to extract detailed data from XFOIL. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Karcher, Cody↗
DOE OSTI2020

A DNN surrogate unsteady aerodynamic model for wind turbine loads calculations

A recurrent deep-neural network (DNN) surrogate model capable of modeling the unsteady aerodynamic response and dynamic stall behavior of wind turbine blades has been developed and validated for use in engineering design codes. The model is trained using a subset of the oscillating airfoil experiments conducted at the Ohio State University wind tunnel. The predictions from our DNN model show excellent agreement with the measured data and, in all cases, a marked improvement over the state-of-the-art unsteady aerodynamic models. The DNN-based unsteady aerodynamics model was integrated with OpenFAST to perform full-turbine load computations for the NREL-5MW rotor. The largest differences are observed for the inboard stations, particularly in the pitching moment response, when using the new surrogate model compared to the other models available in OpenFAST.

17 WIND ENERGY↗
DOE OSTI2022

Leading Edge Microspoilers for Load Dumping in Wind Turbine Rotors

As rotor designs have grown in size and flexibility, new design challenges have arisen that could benefit from novel control strategies. Leading edge microspoilers (LEMS) have been shown to effectively reduce forces on airfoils by inducing stall at lower angles of attack. This paper investigates how LEMS can be used to reduce blade loading on large, flexible, downwind rotors during design-limiting design load cases. During shutdown in turbulent flows near cutout speed, LEMS could reduce the tip deflection spikes toward the tower by over 50% and keep flapwise root bending moments below normal operating conditions, thus eliminating these as design-driving load cases. In power producing load cases, deploying LEMS for a short period of time during a load spike can be effective to reduce toward-tower tip deflections without significantly impacting power produced, assuming these load spikes can be identified by a controller. Leveraging this technology could allow for lower specific power machines to be designed.

17 WIND ENERGY↗
DOE OSTI2021

Design of High-Deflection Foils MHK Applications - FEA models

The Ocean Renewable Power Company's (ORPC's) goal is to design, develop, and test hydrofoils with large deflections. The effects of the deflections on cross-flow turbine performance would be evaluated in order to inform design considerations for full-scale water turbines and other marine hydrokinetic devices. Finite element models - NASTRAN files Model scale turbines tested in UNH tow tank Model loads from CFD models

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Design of high-deflection foils MHK applications - FEA models - Helical turbines

The Ocean Renewable Power Company's (ORPC's) goal is to design, develop, and test hydrofoils with large deflections. The effects of the deflections on cross-flow turbine performance would be evaluated in order to inform design considerations for full-scale water turbines and other marine hydrokinetic devices. FEA models - NASTRAN Helical foil turbines tested at UNH tow tank Glass and carbon composite material properties Loads derived from CFD models

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Design of high-deflection foils MHK applications - CFD models - Helical turbines

The Ocean Renewable Power Company's (ORPC's) goal is to design, develop, and test hydrofoils with large deflections. The effects of the deflections on cross-flow turbine performance would be evaluated in order to inform design considerations for full-scale water turbines and other marine hydrokinetic devices. CFD models of helical model scale turbines tested at UNH OpenFOAM v1912 Tip Speed Ratio (TSR) = 3.00 Different strut configurations

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Design of high deflection foils for MHK applications - CFD files

The Ocean Renewable Power Company's (ORPC's) goal is to design, develop, and test hydrofoils with large deflections. The effects of the deflections on cross-flow turbine performance would be evaluated in order to inform design considerations for full-scale water turbines and other marine hydrokinetic devices. OpenFOAM V1912 files for straight foil model scale turbines in the University of New Hampshire tow tank. Strut Locations = (0.13, 0.225, 0.450, 0.675, 0.900) [m] Tip speed ratio = 2.40

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Advanced Airfoils for Efficient Combined Heat and Power

This poster summarizes a recent effort to use advanced materials, additive manufacturing, and advanced cooling designs to increase the gas turbine inlet temperature for small (<10MW) gas turbines typically used in combined heat and power applications.

Straub, Douglas↗
DOE OSTI2020

Koopman-Based Approach to Nonintrusive Reduced Order Modeling: Application to Aerodynamic Shape Optimization and Uncertainty Propagation

A methodology for nonintrusive projection-based nonlinear model reduction originally presented by Renganathan et al. is further extended here toward parametric systems with a focus on application to aerospace design. Specifically, the method is extended to address static systems with parametric geometry (that deforms the mesh) in addition to parametric freestream boundary conditions. The main idea is to first perform a transformation on the governing equations such that it is lifted to a higher-dimensional but linear underdetermined system. This enables one to extract the system matrices easily as compared to that of the original nonlinear system. The underdetermined system is closed with a set of model-dependent nonlinear constraints upon which the model reduction is finally performed. The methodology is validated on the subsonic and transonic inviscid flows past the NACA0012 and the RAE2822 airfoils with parametrized shapes. The utility of the approach is further demonstrated by applying it to two common problems in aerospace design, namely, derivative-free global optimization and parametric uncertainty quantification with Monte Carlo sampling. Overall, the methodology is shown to achieve accuracy up to 5% and computational speedup of two to three orders of magnitude relative to the full order model. Comparison against another nonintrusive model reduction method revealed that the proposed approach is more robust, accurate, and retains the consistency between the state variables.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Active Aerodynamic Load Control for Wind Turbines

The goal of this project was to develop and demonstrate an advanced dielectric barrier discharge (DBD) plasma actuator technology. We set out to demonstrate the efficacy and impact of the new actuator technology as a key component of an active load control system for wind turbines. A DBD plasma actuator consists of a thin layer of dielectric material separating a pair of offset electrodes. One of those electrodes is embedded between the dielectric layer and a non-conductive substrate, while the other is exposed to air. When driven by an appropriate high voltage waveform, the device ionizes the air near the surface of the dielectric and adjacent to the exposed electrode. Collisions between the ions in the plasma and neutral air molecules result in a wall-jet – a region of induced air velocity that can be used to modify the flow around a lifting body. Use of the device near the trailing edge of a wind turbine blade, designed in such a way as to amplify the effects of the flow-modifying device, can result in large changes to the global forces experienced by the blade. Because of the fast response time of the device, it can allow the turbine to react in real time to changes in the wind associated with turbulence, wind shear, gusts, and the like, when paired with appropriate sensors and control algorithms. The goal of this project was to increase the capacity of the device to induce velocity on its surface at the levels required by large, utility-scale wind turbines. The first technical goal was to increase the induced velocity from the current industry-best of about 4 m/s to 10 m/s by modifying the electrical waveform used to drive the device and by introducing a semi-conductive surface coating to control electrostatic charge build-up on the surface. The second goal was to use the device to modify the lift on a representative airfoil in a wind tunnel, demonstrating a reduction in lift coefficient of 0.2 or better. The third goal was to produce an actuator-induced velocity of 20 m/s. Alongside our partners at the University of Texas at Dallas, we also applied modern, advanced design methods to optimize the impact of the technology on the design of wind turbines. We also had planned to install a segmented, active load control system on a test turbine to demonstrate the ability to reduce unsteady aerodynamic forces on the turbine associated with changes in the wind. The highest induced velocity achieved during this research was 11 m/s. However, practical design constraints limited the change in lift coefficient to about 0.12 for a representative airfoil in the wind tunnel at a Reynolds number of 400,000. The primary conclusion is that the plasma actuator control authority remains insufficient for practical purposes when extrapolated to Reynolds numbers over 1 million. The potential impact of the active lift control concept was evaluated through detailed simulations for three wind turbine sizes: a 3.4MW onshore turbine, a 10MW offshore turbine, and a 15MW offshore turbine. A feedback control system was designed for each turbine within two scenarios: one where the active lift control is used as a retrofit capability on the baseline design, and the other where the designers were permitted to “upscale” the turbines in order increase annual energy production. The levelized cost of energy was then evaluated for the range of turbine sizes and design configuration. It was found that the LCOE reduction associated with active lift control fell in the range of 0.7% to 7.2%, with the highest reduction associated with upscaling the 3.4MW turbine.

17 WIND ENERGY↗
DOE OSTI2026

FOILPOLARS (Grassmannian Foil Shape Sweeps for Polar Generation) [SWR-26-095]

FOILPOLARS (Grassmannian Foil Shape Sweeps for Polar Generation): Multifidelity aerodynamic polar data generation for hydrofoil/tidal-turbine airfoil sections. Foilpolars ties together three pieces: *AeroSandbox supplies the baseline airfoil coordinates (UIUC database). *G2Aero parameterizes those shapes on a Grassmannian manifold (Karcher mean + PGA basis) and samples new perturbed shapes around that basis. *XFoil (panel method) and NeuralFoil (neural-network surrogate, shipped with AeroSandbox) each solve the resulting shapes for lift, drag, moment, and pressure at the swept angles of attack, Reynolds numbers, and n_crit values. Design optimization of foil shapes in a computationally efficient way requires polars data across many candidate shapes, not just a handful of baseline foils. However, high-fidelity CFD at that scale is too costly, and naive shape perturbation strays from realistic geometries. FOILPOLARS addresses this by loading baseline airfoils (via AeroSandbox) and mapping them onto a Grassmannian manifold (via G2Aero), computing a Karcher mean and principal geodesic analysis (PGA) basis. New shapes are sampled by perturbing PGA coefficients, keeping them close to the manifold of realistic foils. Each sampled shape is evaluated across a configurable sweep of angle of attack, Reynolds number, and critical amplification factor using two solvers: XFoil (panel method) and NeuralFoil (neural-network surrogate), producing a paired dataset of lift, drag, moment, pressure, convergence, and confidence, indexed alongside each shape's PGA coefficients and shared Grassmannian basis in a single xarray dataset. From this, FOILPOLARS produces convergence summaries and comparison plots per shape, Reynolds number, and n_crit. A command-line interface exposes each pipeline stage independently, supporting data-driven design, optimization, and machine-learning workflows for foils.

Sandhu, Rimple [National Laboratory of the Rockies↗
DOE OSTI2024

High Temperature Additive Architectures for 65% Efficiency (Final Technical Report)

This project aimed to develop advanced high-temperature additive components that contribute towards the DOE’s goal for advanced gas turbines that are capable of at least 65% efficiency in combined cycle application. The objective was to leverage state-of-the-art additive manufacturing to develop an innovative stage 1 turbine nozzle (S1N) that can provide cooling flow savings while maintaining the component durability expected in today’s gas turbines. The program had two phases. Phase I was a conceptual phase for novel advanced cooling designs enabled by additive manufacturing, as well as proposals for validation. Phase II included execution of the Phase I conceptual design, including manufacturing of prototype hardware and validation within an environment that is similar to engine operation. During Phase I of the program, the team devised a concept to reduce cooling air usage. The cooling air used in the side walls is filmed out along the side walls, while the cooling air used in the airfoil is eventually directed to near-wall channels and exits holes along the airfoil trailing end. During this program, the team performed additive trials to analyze the geometric limitations of additive manufacturing. This helped the team understand minimum wall thicknesses, hole sizes, and cooling channel dimensions among other limits. Phase II of this program pushed GE Vernova beyond its previous experience of designing and manufacturing an additively manufactured hot gas path component. Modern hot gas path components utilize material chemistries that are traditionally hard to weld, such as cast Renè 108, and exhibit solidification cracking when additively manufactured using Direct Metal Laser Melting (DMLM). Note that AM108 is a powder form of Renè 108. A S1N with advanced cooling is larger and more complex than parts previously built by additive manufacturing and required new learnings to resolve risks around solidification cracking. Finally, the team validated the design in a combustion rig that replicated operation in a gas turbine. In order to properly quantify the benefits of the new additive design, a baseline was also tested in the rig and operated under the same conditions. In addition, an uncertainty analysis was done to quantify any sources of error that could impact the results. At the end of the validation effort, it was determined that the additive nozzle exceeded the 15% reduction in cooling flow goal even with the worst-case assumptions for uncertainty.

03 NATURAL GAS↗
DOE OSTI2021

Aero-structural design and optimization of 50 MW wind turbine with over 250-m blades

The quest for reduced levelized cost of energy has driven significant growth in wind turbine size; however, larger rotors face significant technical and logistical challenges. The largest published rotor design is 25 MW, and here we consider an even larger 50 MW design with blade length over 250 m. This paper shows that a 50 MW design is indeed possible from a detailed engineering perspective and presents a series of aero-structural blade designs, and critical assessment of technology pathways and challenges for extreme-scale rotors. The 50 MW rotor design begins with Monte Carlo simulations focused on optimizing carbon spar cap and root design. A baseline design resulted in a 250-m blade with mass of 502 tonnes. Subsequently, an aero-structural design and optimization were performed to reduce the blade mass/cost with more than 25% mass reduction and 30% cost reduction by determining optimal blade chord and airfoil thickness for best aero-structural performance.

Yao, Shulong↗
DOE OSTI2020

Variable-fidelity multipoint aerodynamic shape optimization with output-based adapted meshes

This work presents a method to control the discretization error in multipoint aerodynamic shape optimization using output-based adapted meshes. The meshes are adapted via adjoint-based error estimates, taking into account both the objective and constraint output errors. A multi-fidelity optimization framework is then developed by taking advantage of the variable fidelity offered by adaptive meshes. The objective functional and its sensitivity at each design point (operating condition) are first evaluated on the same initial coarse mesh, which is then subsequently adapted for each design point individually as the shape optimization proceeds. The effort to set up the optimization is minimal since the initial mesh can be fairly coarse and easy to generate. As the shape approaches the optimal design, the mesh at each design point becomes finer, in regions necessary for that particular operating condition. The multi-fidelity framework is tightly coupled with the objective error estimation to ensure the optimization accuracy at each fidelity. Computational savings arise from a reduction of the mesh size when the design is far from optimal and avoiding an exhaustive search on low-fidelity meshes. The proposed method is demonstrated on multipoint drag minimization problems of a transonic airfoil with lift and area constraints. Improved accuracy and efficiency are shown compared to traditional fixed-fidelity optimization with a fixed computational mesh.

42 ENGINEERING↗
DOE OSTI2020

Distributed Aerodynamic Control using Active Trailing-Edge Flaps for Large Wind Turbines

This work presents a numerical framework to investigate distributed aerodynamic control devices for application in large wind turbines. Tool capabilities were extended to facilitate multiple aerodynamic polar tables. The airfoil aerodynamics characteristics were automatically determined, and blade-pitch, generator-torque, and trailing-edge-flap controllers were tuned in-the-loop according to a specific blade design. This automated workflow allows analysis and optimization of trailing-edge flaps, enabling codesign studies. Results targeted reductions of root-flap-bending moment derivatives. The applied trailing-edge-flap control reduced the standard deviation of root-flap-bending moments by more than 6% and benefit related parameters, e.g., reduce blade-tip deflections, by up to 8%. Because of varying thrust distributions along the blade span, different flap designs have nonlinear characteristics in terms of the control objective and show best performance when located at the radial position with maximum thrust. In general, larger flaps provide a greater influence to reduce the target control objective.

17 WIND ENERGY↗