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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

High-Power Impulse Magnetron Sputter Deposition of Boron Carbide with Full-Face Erosion Magnetron and Mixed Ar-Ne Plasma

Boron carbide (B 4 C) is an attractive inertial confinement fusion ablator material. The fabrication of B4C ablators by magnetron sputtering requires process optimization. To increase process flexibility, here we explore high-power impulse magnetron sputter (HiPIMS) deposition of B 4 C in pure Ar and mixed Ar-Ne plasmas. Here, the results show that higher plasma discharge currents can be reached with a mixed Ar-Ne plasma in the entire working pressure range studied (5 𝑡𝑜 50 mTorr). At 45 mTorr with 10% of Ne in the Ar-Ne mix, high peak target current densities of ~1 A cm −2 were demonstrated. Films deposited with such a mixed Ar-Ne plasma with a full-face erosion magnetron source on substrates biased at −25 V exhibited higher density and improved mechanical properties, albeit with higher compressive residual stresses compared to the case of HiPIMS deposition in a pure Ar plasma. This work demonstrates additional process flexibility of the HiPIMS discharge mode for the deposition of B 4 C coatings.

Ablator capsule↗
NASA NTRS2005

Improvements in Fabrication of Sand/Binder Cores for Casting

Three improvements have been devised for the cold-box process, which is a special molding process used to make sand/binder cores for casting hollow metal parts. These improvements are: The use of fiber-reinforced composite binder materials (in contradistinction to the non-fiber-reinforced binders used heretofore), The substitution of a directed-vortex core-blowing subprocess for a prior core-blowing process that involved a movable gassing plate, and The use of filters made from filtration-grade fabrics to prevent clogging of vents. For reasons that exceed the scope of this article, most foundries have adopted the cold-box process for making cores for casting metals. However, this process is not widely known outside the metal-casting industry; therefore, a description of pertinent aspects of the cold-box process is prerequisite to a meaningful description of the aforementioned improvements. In the cold-box process as practiced heretofore, sand is first mixed with a phenolic resin (considered to be part 1 of a three-part binder) and an isocyanate resin (part 2 of the binder). Then by use of compressed air, the mixture is blown into a core box, which is a mold for forming the core. Next, an amine gas (part 3 of the binder) that acts as a catalyst for polymerization of parts 1 and 2 is blown through the core box. Alternatively, a liquid amine that vaporizes during polymerization can be incorporated into the sand/resin mixture. Once polymerization is complete, the amine gas is purged from the core box by use of compressed air. The finished core is then removed from the core box.

Bakhitiyarov, Sayavur I.↗
DOE OSTI2019

I n s i t u observation of a phase transition in silicon carbide under shock compression using pulsed x-ray diffraction

The behavior of silicon carbide (SiC) under shock compression is of interest due to its applications as a high-strength ceramic and for general understanding of shock-induced polymorphism. Here we use the Matter in Extreme Conditions beamline of the Linac Coherent Light Source to carry out a series of time-resolved pump-probe x-ray diffraction measurements on SiC laser-shocked to as high as 206 GPa. Experiments on single crystals and polycrystals of different polytypes show a transformation from a low-pressure tetrahedral phase to the high-pressure rocksalt-type (B1) structure. We directly observe coexistence of the low- and high-pressure phases in a mixed-phase region and complete transformation to the B1 phase above 200 GPa. The densities measured by x-ray diffraction are in agreement with both continuum gas-gun studies and a theoretical B1 Hugoniot derived from static-compression data. Time-resolved measurements during shock loading and release reveal a large hysteresis upon unloading, with the B1 phase retained to as low as 5 GPa. The sample eventually reverts to a mixture of polytypes of the low-pressure phase at late times. Our study demonstrates that x-ray diffraction is an effective means to characterize the time-dependent structural response of materials undergoing shock-induced phase transformations at megabar pressures.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2017

Evaluation of Full Reynolds Stress Turbulence Models in FUN3D

Full seven-equation Reynolds stress turbulence models are a relatively new and promising tool for todays aerospace technology challenges. This paper uses two stress-omega full Reynolds stress models to evaluate challenging flows including shock-wave boundary layer interactions, separation and mixing layers. The Wilcox and the SSG/LRR full second-moment Reynolds stress models have been implemented into the FUN3D (Fully Unstructured Navier-Stokes Three Dimensional) unstructured Navier-Stokes code and are evaluated for four problems: a transonic two-dimensional diffuser, a supersonic axisymmetric compression corner, a compressible planar shear layer, and a subsonic axisymmetric jet. Simulation results are compared with experimental data and results using the more commonly used Spalart-Allmaras (SA) one-equation and the Menter Shear Stress Transport (SST-V) two-equation turbulence models.

reynolds averaging↗
NASA NTRS2017

Evaluation of Full Reynolds Stress Turbulence Models in FUN3D

Full seven-equation Reynolds stress turbulence models are promising tools for today’s aerospace technology challenges. This paper examines two such models for computing challenging turbulent flows including shock-wave boundary layer interactions, separation and mixing layers. The Wilcox and the SSG/LRR full second-moment Reynolds stress models have been implemented into the FUN3D (Fully Unstructured Navier-Stokes Three Dimensional) unstructured Navier-Stokes code and were evaluated for four problems: a transonic two-dimensional diffuser, a supersonic axisymmetric compression corner, a compressible planar shear layer, and a subsonic axisymmetric jet. Simulation results are compared with experimental data and results computed using the more commonly used Spalart-Allmaras (SA) one-equation and the Menter Shear Stress Transport (SST-V) two-equation turbulence models.

reynolds averaging↗
DOE OSTI2020

An experimental investigation of flame and autoignition behavior of propane

We report autoignition delay time data are one important means to develop, quantify, and validate fundamental understanding of combustion chemistry at low temperatures (T<1200 K). However, low-temperature chemistry often has higher uncertainties and scatter in the experimental data compared with high-temperature ignition data (T>1200 K). In this study, autoignition properties of propane and oxygen mixtures were investigated using the University of Michigan rapid compression facility in order to understand the effects of ignition regimes on low-temperature ignition data. For the first time for propane, autoignition delay times were determined from pressure histories, and autoignition characteristics were simultaneously recorded using highspeed imaging of the test section through a transparent end-wall. Propane mixtures with fuel-to-O 2 equivalence ratios of φ = 0.25 and φ = 0.5 and O 2 -to-inert gas molar ratios of 1:3.76 were studied over the pressure range of 8.9 to 11.3 atm and the temperature range of 930 – 1070 K. The results showed homogeneous or strong autoignition occurred for all φ = 0.25 experiments, and inhomogeneous or mixed autoignition occurred for all φ = 0.5 experiments. While a limited temperature range is covered in the study, importantly the data span predicted transitions in autoignition behavior, allowing validation of autoignition regime hypotheses. Specifically, the results agree well with strong-autoignition limits proposed based on the Sankaran Criterion. The autoignition delay time data at the strong-ignition conditions are in excellent agreement with predictions using a well-validated detailed reaction mechanism from the literature and a zerodimensional modeling assumption. However, the experimental data at the mixed autoignition conditions were systematically faster than the model predictions, particularly at lower temperatures (T< ~970 K). The results are an important addition to the growing body of data in the literature that show mixed autoignition phenomena are important sources of the higher scatter observed in the low-temperature autoignition data for propane and other fuels. The results are discussed in terms of different methods to capture the effects of pre-autoignition heat release associated with mixed autoignition conditions and thereby address some of the discrepancies between kinetic modeling and experimental measurements.

42 ENGINEERING↗
DOE OSTI2021

Achieving record hot spot energies with large HDC implosions on NIF in HYBRID-E

HYBRID-E is an inertial confinement fusion implosion design that increases energy coupled to the hot spot by increasing the capsule scale in cylindrical hohlraums while operating within the current experimental limits of the National Ignition Facility. HYBRID-E reduces the hohlraum scale at a fixed capsule size compared to previous HYBRID designs, thereby increasing the hohlraum efficiency and energy coupled to the capsule, and uses the cross-beam energy transfer (CBET) to control the implosion symmetry by operating the inner (23° and 30°) and outer (44° and 50°) laser beams at different wavelengths (Δλ> 0). Small case to capsule ratio designs can suffer from insufficient drive at the waist of the hohlraum. We show that only a small amount of wavelength separation between the inner and outer beams (Δλ1-2 Å) is required to control the symmetry in low-gas-filled hohlraums (0.3 mg/cm3 He) with enough drive at the waist of the hohlraum to symmetrically drive capsules 1180 μm in outer radius. This campaign is the first to use the CBET to control the symmetry in 0.3 mg/cm3 He-filled hohlraums, the lowest gas fill density yet fielded with Δλ> 0. We find a stronger sensitivity of hot spot P2 in μm per Angstrom (40–50 μm/Å wavelength separation) than observed in high-gas-filled hohlraums and previous longer pulse designs that used a hohlraum gas fill density of 0.6 mg/cm3. There is currently no indication of transfer roll-off with increasing Δλ, indicating that even longer pulses or larger capsules could be driven using the CBET in cylindrical hohlraums. We show that the radiation flux symmetry is well controlled during the foot of the pulse, and that the entire implosion can be tuned symmetrically in the presence of the CBET in this system, with low levels of laser backscatter out of the hohlraum and low levels of hot electron production from intense laser–plasma interactions. Radiation hydrodynamic simulations can accurately represent the early shock symmetry and be used as a design tool, but cannot predict the late-time radiation flux symmetry during the peak of the pulse, and semi-empirical models are used to design the experiments. Deuterium–tritium (DT)-layered tests of 1100 μm inner radius implosions showed performance close to expectations from simulations at velocities up to ~360 km/s, and record yields at this velocity, when increasing the DT fuel layer thickness to mitigate hydrodynamic mixing of the ablator into the hot spot as a result of defects in the ablator. However, when the implosion velocity was increased, mixing due to these defects impacted performance. The ratio of measured to simulated yield for these experiments was directly correlated with the level of observed mixing. These simulations suggest that reducing the mixing, e.g., by improving the capsule defects, could result in higher performance. In addition, future experiments are planned to reduce the coast time at this scale, delay between the peak compression and the end of the laser, to increase the hot spot convergence and pressure. To reduce the coast time by several hundred ps compared to the 1100 μm inner radius implosions, HYBRID-E has also fielded 1050 μm inner radius capsules, which resulted in higher hot spot pressure and a fusion energy yield of ~170 kJ.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Revolutionizing Turbine Cooling with Micro-Architectures Enabled by Direct Metal Laser Sintering

The objective of this research effort was to explore innovative cooling architectures enabled by additive manufacturing techniques for improved turbine cooling performance. The ability to create complex internal geometries was leveraged to better distribute coolant as well as to integrate inherently unstable flow devices to enhance internal and external heat transfer. This was accomplished with a multi-faceted approach including analytical, experimental, and computational components. This final report documents progress during the total 4.25 year effort that was extended (at no additional cost) from the original 3-year cooperative agreement. Prior to starting the project, significant effort was invested in investigating innovative cooling designs from the open literature. When the project started, we quickly down-selected to 4 configurations: impingement jet fluidic oscillators (for internal leading edge cooling), reverse film cooling (for pressure surface), sweeping film cooling jets (for suction surface), and trailing edge slot cooling with microchannels. During the 2nd year, the reverse film cooling design was shown to be sub-optimal and work on that topic was halted. The three remaining technologies were integrated into a large scale nozzle guide vane and installed into a low-speed linear cascade facility for further interrogation. Initial results showed the sweeping film cooling jets (on the suction surface) to be the most promising technology compared to a baseline diffusion shaped film hole (777 design). The benefit was particularly evident at high blowing ratios (>1.5) when the 777 coolant film separated from the downstream surface. Benefits were also evident at elevated freestream turbulence levels. The leading edge cooling with unsteady jets was less effective in terms of peak or average cooling – however it was superior to round hole impingement cooling in terms of spatial uniformity. Finally, the trailing edge cooling design with micro-channels was scrapped in favor of a pinned arrangement with centerbody. During the 3rd year, the same three technologies were integrated into a transonic linear cascade for an assessment of compressibility effects. Again, the sweeping film cooling jets proved superior at high blowing ratios while the unsteady leading edge impingement and trailing edge pin-fins with centerbody designs yielded mixed results. Finally, during the 4th and final year, these 3 technologies were integrated into a direct metal laser sintered (DMLS) nozzle guide vane for testing in a high temperature, transonic annular vane cascade. The facility matches the flow temperature, Mach number, and coolant pressure ratios of an actual gas turbine. Before doing this, an additional series of tests were completed to validate a redesigned trailing edge cooling architecture. This final design included a centerbody with triangular pins between the centerbody and the vane external skin. The majority of these triangular pins are fabricated with a 30% gap to the centerbody – reducing their pressure drop considerably while still providing excellent heat transfer augmentation. This additional test campaign required an additional 3-month extension request to complete testing in the high temperature NGV test facility (Turbine Reacting Flow Rig – TuRFR). Testing of the DMLS vane in TuRFR pitted the 3 innovative cooling technologies against more traditional technologies (shaped 777 film hole, round impingement jet, and full pin arrangement in the trailing edge. The sweeping film cooling jets (on the suction surface) showed approximately 15% improvement in overall effectiveness compared to the 777 film hole while the trailing edge showed up to 20% improvement. The leading edge impingement was disappointing with a substantially lower effectiveness than traditional direct impingement. In summary, the study was successful in demonstrating that DMLS-enabled cooling technologies can yield significant gains in cooling performance.

03 NATURAL GAS↗
NASA NTRS1983

Three-dimensional compressible viscous analysis of mixer nozzles

An analysis-based design procedure for compound-mixer exhaust nozzles is presented and compared to test data. The design approach is based on two numerical solutions to the 3-D viscous compressible Navier-Stokes equations: an equation splitting technique used for the analysis of the core and bypass flow, and a parabolic marching scheme used in the analysis of the mixing duct. The selection of the analytical methods through test data comparisons and their coupling into an integrated design system are discussed. NASA test data is used to demonstrate the validity of the computations from the exhaust system rating station, upstream of the mixer lobe, to the nozzle throat. An estimate is made of the savings in development time and cost utilizing the new procedure.

Goyal, R. K.↗
NASA NTRS1994

Shock recovery analogs and the origin of mesosiderites

The origin of mesosiderites, which consist of approximately equal-weight proportions of Fe-Ni metal and silicates (gabbros, basalts, orthopyroxenites, dunites), remains an interesting and complex problem in meteoritics. There is general agreement that multiple impact events were probably involved in the formation of these brecciated stony-iron meteorites, but given the heterogeneity of mesosiderites, additional processes have been invoked to explain the unique and intricate textural and compositional makeup of mesosiderites. We conducted a series of shock recovery experiments to test the impact event(s) scenario. The results indicated significant similarities between the shocked analogs and many mesosiderites. We have compared our analogs with a suite of thin sections of Barea mesosiderite. I have conducted a series of flash heating experiments in which equal-weight proportions of gabbro and stainless steel (SS304) powders were compressed into small charges and heated under reducing conditions for short times. These experiments were used to bracket localized, peak postshock temperatures in our analog shots and to compare the mixing relations between the silicate and metal. The shock recovery experiments used porous metal-silicate powder starting mixtures, therefore our experiments are most analogous to an impact scenario where the target is an asteroidal regolith surface composed of a loose mixture of Fe-Ni metal and heterogeneous silicates. Analog experiments may really describe a secondary impact process similar to the late-stage, localized impact melting event. This leaves one of the crucial questions about mesosiderite genesis unanswered, namely what is the source of the Fe-Ni metal that is so intimately distributed in these meteorites?

Rowan, L. R.↗
NASA NTRS1998

Performance of Low Dissipative High Order Shock-Capturing Schemes for Shock-Turbulence Interactions

Accurate and efficient direct numerical simulation of turbulence in the presence of shock waves represents a significant challenge for numerical methods. The objective of this paper is to evaluate the performance of high order compact and non-compact central spatial differencing employing total variation diminishing (TVD) shock-capturing dissipations as characteristic based filters for two model problems combining shock wave and shear layer phenomena. A vortex pairing model evaluates the ability of the schemes to cope with shear layer instability and eddy shock waves, while a shock wave impingement on a spatially-evolving mixing layer model studies the accuracy of computation of vortices passing through a sequence of shock and expansion waves. A drastic increase in accuracy is observed if a suitable artificial compression formulation is applied to the TVD dissipations. With this modification to the filter step the fourth-order non-compact scheme shows improved results in comparison to second-order methods, while retaining the good shock resolution of the basic TVD scheme. For this characteristic based filter approach, however, the benefits of compact schemes or schemes with higher than fourth order are not sufficient to justify the higher complexity near the boundary and/or the additional computational cost.

Sandham, N. D.↗
NASA NTRS1998

Performance of Low Dissipative High Order Shock-Capturing Schemes for Shock-Turbulence Interactions

Abstract Accurate and efficient direct numerical simulation of turbulence in the presence of shock waves represents a significant challenge for numerical methods. The objective of this paper is to evaluate the performance of high order compact and non-compact central spatial differencing employing total variation diminishing (TVD) shock-capturing dissipations as characteristic based filters for two model problems combining shock wave and shear layer phenomena. A vortex pairing model evaluates the ability of the schemes to cope with shear layer instability and eddy shock waves, while a shock wave impingement on a spatially-evolving mixing layer model studies the accuracy of computation of vortices passing through a sequence of shock and expansion waves. A drastic increase in accuracy is observed if a suitable artificial compression formulation is applied to the TVD dissipations. With this modification to the filter step the fourth-order non-compact scheme shows improved results in comparison to second-order methods, while retaining the good shock resolution of the basic TVD scheme. For this characteristic based filter approach, however, the benefits of compact schemes or schemes with higher than fourth order are not sufficient to justify the higher complexity near the boundary and/or the additional computational cost.

Sandham, N. D.↗
NASA NTRS1987

Remotely controllable mixing system

A remotely controllable mixing system (210) in which a plurality of mixing assemblies (10a-10e) are arranged in an annular configuration, and wherein each assembly (10) employs a central chamber (16) and two outer, upper and lower, chambers (12, 14). Valves (18, 20) are positioned between chambers, and these valves (18, 20) for a given mixing assembly (10) are operated by upper and lower control rotors (29), which in turn are driven by upper and lower drive rotors (270, 270b). Additionally, a hoop (278) is compressed around upper control rotors (29) and a hoop (278b) is compressed around lower control rotors (29) to thus insure constant frictional engagement between all control rotors (29) and drive rotors (270, 270b). The drive rollers (270, 270b) are driven by a motor (213).

Belew, Robert R.↗
NASA NTRS2004

Part 1 of a Computational Study of a Drop-Laden Mixing Layer

This first of three reports on a computational study of a drop-laden temporal mixing layer presents the results of direct numerical simulations (DNS) of well-resolved flow fields and the derivation of the large-eddy simulation (LES) equations that would govern the larger scales of a turbulent flow field. The mixing layer consisted of two counterflowing gas streams, one of which was initially laden with evaporating liquid drops. The gas phase was composed of two perfect gas species, the carrier gas and the vapor emanating from the drops, and was computed in an Eulerian reference frame, whereas each drop was tracked individually in a Lagrangian manner. The flow perturbations that were initially imposed on the layer caused mixing and eventual transition to turbulence. The DNS database obtained included transitional states for layers with various liquid mass loadings. For the DNS, the gas-phase equations were the compressible Navier-Stokes equations for conservation of momentum and additional conservation equations for total energy and species mass. These equations included source terms representing the effect of the drops on the mass, momentum, and energy of the gas phase. From the DNS equations, the expression for the irreversible entropy production (dissipation) was derived and used to determine the dissipation due to the source terms. The LES equations were derived by spatially filtering the DNS set and the magnitudes of the terms were computed at transitional states, leading to a hierarchy of terms to guide simplification of the LES equations. It was concluded that effort should be devoted to the accurate modeling of both the subgridscale fluxes and the filtered source terms, which were the dominant unclosed terms appearing in the LES equations.

Okong'o, Nora A.↗
DOE OSTI2022

Alkyl dialkoxyalkanoates as bioderived, high cetane diesel fuels

A fuel for an internal combustion engine includes a C 5 to C 30 dialkoxyalkanoate corresponding to formula (I), wherein the R 1 group is —H or a —CH 3 group, the R 2 and R 2 ′ groups are alkyl groups independently selected to have 1 to 9 carbon atoms; and the R 3 group is selected to have 1 to 9 carbon atoms. The compounds described herein may be used as neat fuels or mixed fuels (with diesel, biodiesel, jet fuel, marine fuel or other fuel compounds) in autoignition or spark ignition engines, such as diesel engines, gasoline (spark ignition) engines, MCCI, Homogeneous Charge Compression Ignition (HCCI) engines, or more generally in Low-Temperature Gasoline Combustion (LTGC) engines (using gasoline-like fuels), that have the high-efficiency advantages of HCCI but can operate with some level of charge inhomogeneities. Methods of making these compounds are environmentally friendly and can be done in a continuous manner.

Myllenbeck, Nicholas↗
DOE OSTI2020

Investigation of finite-volume methods to capture shocks and turbulence spectra in compressible flows

The aim of the present paper is to provide a comparison between several finite-volume methods of different numerical accuracy: the second-order Godunov method with PPM interpolation and the high-order finite-volume WENO method. In this work, the results show that while on a smooth problem the high-order method performs better than the second-order one, when the solution contains a shock all the methods collapse to first-order accuracy. In the context of the decay of compressible homogeneous isotropic turbulence with shocklets, the actual overall order of accuracy of the methods reduces to second-order, despite the use of fifth-order reconstruction schemes at cell interfaces. Most important, results in terms of turbulent spectra are similar regardless of the numerical methods employed, except that the PPM method fails to provide an accurate representation in the high-frequency range of the spectra. It is found that this specific issue comes from the slope-limiting procedure and a novel hybrid PPM/WENO method is developed that has the ability to capture the turbulent spectra with the accuracy of a high-order method, but at the cost of the second-order Godunov method. Overall, it is shown that virtually the same physical solution can be obtained much faster by refining a simulation with the second-order method and carefully chosen numerical procedures, rather than running a coarse high-order simulation. Our results demonstrate the importance of evaluating the accuracy of a numerical method in terms of its actual spectral dissipation and dispersion properties on mixed smooth/shock cases, rather than by the theoretical formal order of convergence rate.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1990

A computational design tool for scramjet combustor film cooling and fuel mixing predictions

A methodology for the analysis of a film cooled combustor of a hydrogen-fueled, supersonic combustion ramjet (scramjet) is presented. The SHIP3D parabolic flow code, based on an extension of the pressure-correction method of Patankar and Spalding for compressible flow is used to compute the flow field in the combustor. The effect of film cooling on the overall vehicle performance is then calculated using the one-dimensional, multistep cycle code, CPIPE. Results are presented for a conceptual combustor at Mach 16 flight conditions. It is seen that film cooling can have a significant effect on the engine performance.

Kamath, Pradeep S.↗
DOE OSTI2020

Real Fuel Modeling for Gasoline Compression Ignition Engine

Increasing regulatory demand for efficiency has led to development of novel combustion modes such as HCCI, GCI and RCCI for gasoline light duty engines. In order to realize HCCI as a compression ignition combustion mode system, in-cylinder compression temperatures must be elevated to reach the autoignition point of the premixed fuel/air mixture. This should be co-optimized with appropriate fuel formulations that can autoignite at such temperatures. CFD combustion modeling is used to model the auto ignition of gasoline fuel under compression ignition conditions. Using the fully detailed fuel mechanism consisting of thousands of components in the CFD simulations is computationally expensive. To overcome this challenge, the real fuel is represented by few major components of create a surrogate fuel mechanism. In this study, 9 variations of gasoline fuel sets were chosen as candidates to run in HCCI combustion mode. A study detailing the development of the gasoline real fuel model was performed and various surrogates for gasoline fuel were investigated. The gasoline real fuel model will be used in subsequent CFD modelling activities for the development of an advanced mixed mode combustion system as part of the Department of Energy funded project DE-EE0008478.

Gasoline Compression Ignition, real fuel modeling,↗