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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 757 records · Page 42

Emission FTIR analyses of thin microscopic patches of jet fuel residues deposited on heated metal surfaces

The relationship of fuel stability to fuel composition and the development of mechanisms for deposit formation were investigated. Fuel deposits reduce heat transfer efficiency and increase resistance to fuel flow and are highly detrimental to aircraft performance. Infrared emission Fourier transform spectroscopy was chosen as the primary method of analysis because it was sensitive enough to be used in-situ on tiny patches of monolayers or of only a few molecular layers of deposits which generally proved completely insoluble in any nondestructive solvents. Deposits of four base fuels were compared; dodecane, a dodecane/tetralin blend, commercial Jet A fuel, and a broadened-properties jet fuel particularly rich in polynuclear aromatics. Every fuel in turn was provided with and without small additions of such additives as thiophene, furan, pyrrole, and copper and iron naphthenates.

Lauer, J. L.↗

Nuclear Reactor Heat Extraction for Synthetic Fuel Plants

This report looks at the viability and best approach when producing synthetic fuels using heat and power supplied by advanced nuclear energy systems. The report looks at a low temperature integration pathway with four types of advanced reactors: a pressurized water reactor (PWR), an advanced light water reactor (A-LWR), a sodium fast reactor (SFR), and a high-temperature gas-cooled reactor (HTGR). A failure modes and effects analysis (FMEA) of the coupling system between the nuclear plant and the synthetic fuel systems is performed with the goal of identifying the reliability of such a thermal delivery system. Furthermore, a high temperature pathway is investigated for synfuel coupling to determine if this is more efficient and more cost effective as a coupling approach.

10 - SYNTHETIC FUELS↗

SI Engine Trends: A Historical Analysis with Future Projections

It is well known that spark ignited engine performance and efficiency is closely coupled to fuel octane number. The present work combines historical and recent trends in spark ignition engines to build a database of engine design, performance, and fuel octane requirements over the past 80 years. The database consists of engine compression ratio, required fuel octane number, peak mean effective pressure, specific output, and combined unadjusted fuel economy for passenger vehicles and light trucks. Recent trends in engine performance, efficiency, and fuel octane number requirement were used to develop correlations of fuel octane number utilization, performance, specific output. The results show that historically, engine compression ratio and specific output have been strongly coupled to fuel octane number. However, over the last 15 years the sales weighted averages of compression ratios, specific output, and fuel economy have increased, while the fuel octane number requirement has remained largely unchanged. Using the developed correlations, 10-year-out projections of engine performance, design, and fuel economy are estimated for various fuel octane numbers, both with and without turbocharging. The 10-year-out projection shows that only by keeping power neutral while using 105 RON fuel will allow the vehicle fleet to meet CAFE targets if only the engine is relied upon to decrease fuel consumption. If 98 RON fuel is used, a power neutral fleet will have to reduce vehicle weight by 5%.

Pawlowski, Alexander↗

New perspectives for advanced automobile diesel engines

Computer simulation results are presented for advanced automobile diesel engine performance. Four critical factors for performance enhancement were identified: (1) part load preheating and exhaust gas energy recovery, (2) fast heat release combustion process, (3) reduction in friction, and (4) air handling system efficiency. Four different technology levels were considered in the analysis. Simulation results are compared in terms of brake specific fuel consumption and vehicle fuel economy in km/liter (miles per gallon). Major critical performance sensitivity areas are: (1) combustion process, (2) expander and compressor efficiency, and (3) part load preheating and compound system. When compared to the state of the art direct injection, cooled, automobile diesel engine, the advanced adiabatic compound engine concept showed the unique potential of doubling the fuel economy. Other important performance criteria such as acceleration, emissions, reliability, durability and multifuel capability are comparable to or better than current passenger car diesel engines.

Tozzi, L.↗

Preliminary critical experiments validation of a lattice physic code LATC - 14415

Core and System Integrated Engine for design and analysis (COSINE) is an integrated nuclear engineering code package, which is being developed by State Nuclear Power Software Development Center (SNPSDC) in China. A lattice physics code named LATC is included in COSINE.LATC is a 2D, steady-state code for modeling PWR fuel. A WIMS-D 69 group micro library based on ENDF/B-VI is used and there are two transportation methods in LATC, such as two steps method (collision probability method for cell homogenization, discrete coordinate method for assembly homogenization) and one step method (MOC). The UO{sub 2} fuel assembly, which may contain guide tubes, burnable poisons such as Integral Fuel Burnable Absorbers (IFBA) / Wet Annular Burnable Absorbers (WABA)/ Pyrexes or control rods etc, can be calculated in LATC. LATC provides the required cross-section data for the core physics simulator analysis code in COSINE. In order to evaluate the quality of the LATC, a strategy of validation is researched and applied to the LATC. Firstly, a validation requirement analysis is performed, and the corresponding critical experiments are collected, and then a critical experimental matrix considering the variety of fuel enrichments, fuel pitch and water to uranium ratio is generated. Finally, a comparison of results between LATC using collision probability and discrete coordinate method and critical experiments are made to make sure that the code works well. According to the validation strategy discussed above, the preliminary validation is carried out and critical experiments are calculated according to the critical experimental matrix and results from LATC code are compared with reference results. The result shows that the calculated results agree well with critical experiments, and do not indicate any significant trends with respect to the various conditions considered. (authors)

42 ENGINEERING↗

Irradiation of MiniFuel Targets Bearing TRISO Fuel Compacts (Status Report)

Irradiation testing of MiniFuel compacts bearing tristructural isotropic (TRISO) fuel particles was performed at Oak Ridge National Laboratory (ORNL) to support the development of Kairos Power’s (KP’s) fluoride salt–cooled high-temperature reactor concept. The fuel compacts were fabricated with TRISO fuel particles of different types—including low-enriched uranium oxide, uranium carbide (LEUCO), natural uranium oxide, uranium carbide (NUCO), and low-enriched uranium dioxide (LEUO 2 )—and inserted into MiniFuel irradiation targets. Five targets were assembled and inserted in the High Flux Isotope Reactor (HFIR) for four cycles. The data collected post-irradiation will provide experimental input to validate TRISO fuel performance models for high particle power operations. This report summarizes the completion of the HFIR irradiation, the as-irradiated numerical analysis, and the post-irradiation work performed to date. This work was performed under the Nuclear Science User Facility program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Safeguards Modeling for Advanced Nuclear Facility Design.

Future nuclear fuel cycle facilities will see a significant benefit from considering materials accountancy requirements early in the design process. The Material Protection, Accounting, and Control Technologies (MPACT) working group is demonstrating Safeguards and Security by Design (SSBD) for a notional electrochemical reprocessing facility as part of a 2020 Milestone. The idea behind SSBD is to consider regulatory requirements early in the design process to provide more optimized systems and avoid costly retrofits later in the design process. Safeguards modeling, using single analyst tools, allows the designer to efficiently consider materials accountancy approaches that meet regulatory requirements. However, safeguards modeling also allows the facility designer to go beyond current regulations and work toward accountancy designs with rapid response and lower thresholds for detection of anomalies. This type of modeling enables new safeguards approaches and may inform future regulatory changes. The Separation and Safeguards Performance Model (SSPM) has been used for materials accountancy system design and analysis. This paper steps through the process of designing a Material Control and Accountancy (MC&A) system, presents the baseline system design for an electrochemical reprocessing facility, and provides performance metrics from the modeling analysis. The most critical measurements in the electrochemical facility are the spent fuel input, electrorefiner salt, and U/TRU product output measurements. Finally, material loss scenario analysis found that measurement uncertainties (relative standard deviations) for Pu would need to be at 1% (random and systematic error components) or better in order to meet domestic detection goals or as high as 3% in order to meet international detection goals, based on a 100 metric ton per year plant size.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

Effect of time dependent flight loads on JT9D-7 performance deterioration

The results of a modal transient analysis of the engine/aircraft system are presented. The response of the JT9D to analytically simulated vertical gusts and landings was predicted using a NASTRAN finite element mathematical model of the JT9D/747 propulsion system. The NASTRAN finite element model of the propulsion system included engine structural models of the fan, low/high pressure compressors, diffuser/turbine cases, and high/low pressure rotors, as well as nacelle models of the inlet cowl, tailcone, and wing pylon. The analysis conducted predicts that an insignificant level of JT9D-7 performance deterioration would occur due to a typical vertical gust encounter or a typical revenue service landing. Analysis of a high sink rate landing with a heavy fuel load indicates the possibility of local wear, however, the lack of an accurate dynamic rotor/seal interference model precludes an accurate quantitative evaluation of performance change for this once-per-airframe-life event.

Jay, A.↗

Probabilistic Structural Analysis and Reliability Using NESSUS With Implemented Material Strength Degradation Model

This project included both research and education objectives. The goal of this project was to advance innovative research and education objectives in theoretical and computational probabilistic structural analysis, reliability, and life prediction for improved reliability and safety of structural components of aerospace and aircraft propulsion systems. Research and education partners included Glenn Research Center (GRC) and Southwest Research Institute (SwRI) along with the University of Texas at San Antonio (UTSA). SwRI enhanced the NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) code and provided consulting support for NESSUS-related activities at UTSA. NASA funding supported three undergraduate students, two graduate students, a summer course instructor and the Principal Investigator. Matching funds from UTSA provided for the purchase of additional equipment for the enhancement of the Advanced Interactive Computational SGI Lab established during the first year of this Partnership Award to conduct the probabilistic finite element summer courses. The research portion of this report presents the cumulation of work performed through the use of the probabilistic finite element program, NESSUS, Numerical Evaluation and Structures Under Stress, and an embedded Material Strength Degradation (MSD) model. Probabilistic structural analysis provided for quantification of uncertainties associated with the design, thus enabling increased system performance and reliability. The structure examined was a Space Shuttle Main Engine (SSME) fuel turbopump blade. The blade material analyzed was Inconel 718, since the MSD model was previously calibrated for this material. Reliability analysis encompassing the effects of high temperature and high cycle fatigue, yielded a reliability value of 0.99978 using a fully correlated random field for the blade thickness. The reliability did not change significantly for a change in distribution type except for a change in distribution from Gaussian to Weibull for the centrifugal load. The sensitivity factors determined to be most dominant were the centrifugal loading and the initial strength of the material. These two sensitivity factors were influenced most by a change in distribution type from Gaussian to Weibull. The education portion of this report describes short-term and long-term educational objectives. Such objectives serve to integrate research and education components of this project resulting in opportunities for ethnic minority students, principally Hispanic. The primary vehicle to facilitate such integration was the teaching of two probabilistic finite element method courses to undergraduate engineering students in the summers of 1998 and 1999.

Bast, Callie C.↗

Gains in operational flexibility, safety margins, and cost efficiencies via integrated Plant Reload Optimization platform

The U.S. Department of Energy Light Water Reactor Sustainability Program Risk-Informed Systems Analysis Pathway Plant Reload Optimization Project aims to develop an integrated, comprehensive framework offering an all-in-one solution for reload evaluations with a special focus on optimizing core design. Optimizing the fuel loading pattern is one of the most important considerations in reducing the amount of new fuel used in the core. Due to thousands of possible core configuration options, finding optimal solutions is an unachievable task for a human. The Plant ReLoad Optimization platform, which supports artificial-intelligence-based reactor core designing, is now fully capable of handling realistic problems. The Plant ReLoad Optimization platform development project aims to build a reactor core design tool that includes reactor safety and fuel performance analyses and uses artificial intelligence to support the optimization of core design solutions. The NSGA-II (Non-dominated Sorting Genetic Algorithm II) optimizer was developed and tested within RAVEN (Risk Analysis and Virtual ENvironment) to handle many constraints by using an augmented objectives methodology. The demonstration was performed with constrained multiobjective optimization of a 17 × 17 pressurized-water reactor core loading patterns to minimize fuel cost and maximize fuel cycle length.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of Stable Solid Oxide Electrolysis Cells for Low-Cost Hydrogen Production

The project objective was to demonstrate a solid oxide cell-based steam electrolysis stack that exhibits robustness, reliability, endurance, hydrogen purity, and produces hydrogen at elevated pressure of 2 to 3 bar. Innovative materials and processing methods were evaluated to improve degradation characteristics. Performance improvement focused on nearly all layers involved in the cell and stack assembly. Primary attention was paid to zirconia-ceria interface resistance control via sintering optimization and decrease in degradation from the oxygen electrode by evaluating low strontium (Sr) or Sr-free composition for both the oxygen electrode and current collection layer. Stack robustness was addressed by validating redox tolerance of fuel electrode, confirming capability of cells to survive repeated thermal cycles, studying the effect of pressure on performance and degradation, evaluating the effect of contamination on fuel and oxygen electrode performance and degradation, and identifying mitigation strategies to improve performance. The characterization included evaluation of electrochemical performance and stability followed by microstructural analysis. At the cell level, performance and stability improvements were achieved by incorporating a Sr-free oxygen electrode and a denser oxygen electrode barrier layer. At the stack level, pressurized operation reduces demand on first stage compression, the redox tolerant fuel electrode mitigates risk from service interruptions, and improvements to interconnect coating alleviate chromium (Cr) contamination effects. The denser barrier layer was achieved by adding a sintering aid to the samaria-doped ceria (SDC) composition that reduced sintering temperature by 150 °C. The resulting density was on par with the baseline SDC barrier layer density and the lower sintering temperature resulted in less resistive phase formation during sintering. Button cell tests did not demonstrate a change in performance when exposed to silicon (Si) or manganese (Mn) impurities to the fuel electrode and Cr impurity to the oxygen electrode. More detailed study however is warranted. The project addressed SOEC performance and stability at the cell and stack levels through a systematic approach to known sources of degradation that were combined and tested in three stack tests using an electrolyte supported cell design to allow for evaluation of a variety of fuel and oxygen electrode compositions. STK-82 and STK-83 had identical compositions. STK-100 incorporated the best materials and processing variables developed under this and concurrent projects, and was tested at elevated pressure in steam electrolysis. • STK-82 recovered performance after redox and thermal cycling, demonstrating the robustness of the stack and seals. It exhibited stable performance in testing for 500 hours in SOEC mode, followed by 300 hours of cycling between SOEC and SOFC tests. Degradation during SOEC operation was 1.8 %/ 1,000 hours. • STK-83 generated hydrogen at >80% steam conversion, and oxygen above 98.5 % purity during pressurized operation. Both hydrogen and oxygen were generated at 3 barg pressure without the use of a pressure vessel. In addition to balanced pressure, electrolysis operation at 1 bar differential pressure across anode and cathode was also demonstrated to substantial the robustness of the cell and seal. • STK-100 measured at initial ambient pressure conditions showed an area specific resistance of 1.1 ohm-cm 2 , and STK-83 had 1.3 ohm-cm 2 .

08 HYDROGEN↗

CFD-Based Design of a Filming Injector for N+3 Combustors

An effort was undertaken to perform CFD analysis of fluid flow in Lean-Direct Injection (LDI) combustors with axial swirl-venturi elements coupled with a new fuel-filming injector design for next-generation N+3 combustors. The National Combustion Code (NCC) was used to perform non-reacting and two-phase reacting flow computations on a N+3 injector configuration, in a single-element and a five-element injector array. All computations were performed with a consistent approach towards mesh-generation, spray-, ignition- and kinetics-modeling with the NCC. Computational predictions of the aerodynamics of the injector were used to arrive at an optimal injector design that met effective area, aerodynamics, and fuel-air mixing criteria. LDI-3 emissions (EINOx, EICO and UHC) were compared with the previous generation LDI-2 combustor experimental data at representative engine cycle conditions.

combustion chambers↗

Steady-State Subchannel Thermalhydraulic Assessment of Thorium-Based Fuel Concepts for Use in Pressure Tube Heavy Water Reactors

Thorium is an abundant alternative fertile nuclear fuel that could potentially be implemented in pressure tube heavy water reactors (PT-HWR) in the near future. One of the key stages in developing the thorium-based fuels for PT-HWRs is the reactor core concept, which requires the collaboration of different disciplines, such as neutron physics, thermal-hydraulics, materials, chemistry, safety, and others. Currently there are numerous core concepts under investigation at the Canadian Nuclear Laboratories that involve several types of thorium-based fuels, and that could be implemented in a 700-MWe-class PT-HWR. Four fuel bundle concepts are considered, including i) the reference (or nominal) 37-element bundle; ii) a 37-element modified bundle, with the center element using a different fuel material; iii) a 35-element bundle design, and iv) an 18-element internally cooled annular fuel (ICAF-18) fuel bundle. This study presents preliminary results of the steady-state thermalhydraulic subchannel analyses of the hot channels of different PT-HWR core concepts using thorium-augmented or thorium-based fuels. A follow up study will be initiated to improve the assessment of the proposed cores and associated fuel bundle concepts for thorium-augmented and thorium-based fuels. The computational model will be revisited to include; - Expanding the analysis to cover different power profiles at different burnup stages of the bundle. - Expand the analysis to cover 28.5 kg/s. - Reduce the eccentricity of the 35-element fuel bundle. - Assess the effect of the phenomena not yet included in the subchannel model (such as the effect of cold wall, and gamma heat). - Expand the analysis to include the effect of spacers and junctions. - Compare bundle concepts using other performance indicators (such as burnup, breeding ratio), as optimizing the fuel bundle geometry is a multidisciplinary problem.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Impact of a Bluff Body on a Pressurized Oxy-fuel Flame

Designing an effective burner is vital for the development of pressurized oxy-fuel combustion technologies. In the present work, turbulent jet diffusion burners are adopted for a pressurized oxy-combustor, with a bluff-body employed to create a recirculation zone, thereby stabilizing the flame in such a combustor. The objective of this numerical study is to perform a systematic analysis of the characteristics of such a pressurized non-premixed flame. Specifically, a 15-bar pressurized oxy-fuel combustor of power 100 kWth is modeled by means of the Ansys FLUENT commercial platform, using the Reynolds-averaged Navier-Stokes (RANS) approach. The present work focuses on identifying the aerothermodynamic features of the pressurized oxy-fuel burner with a disk-shape bluff-body. It is shown that the fuel-to-oxidizer stream momentum ratio has a great impact on the temperature profile of the down-fired, co-axial, pressurized oxy-coal, diffusion flame. A parametric study of the blockage ratio of the burner identifies an optimal range for this pressurized burner.

Li, Lei↗

Analyzing machine learning models to accelerate generation of fundamental materials insights

Abstract Machine learning for materials science envisions the acceleration of basic science research through automated identification of key data relationships to augment human interpretation and gain scientific understanding. A primary role of scientists is extraction of fundamental knowledge from data, and we demonstrate that this extraction can be accelerated using neural networks via analysis of the trained data model itself rather than its application as a prediction tool. Convolutional neural networks excel at modeling complex data relationships in multi-dimensional parameter spaces, such as that mapped by a combinatorial materials science experiment. Measuring a performance metric in a given materials space provides direct information about (locally) optimal materials but not the underlying materials science that gives rise to the variation in performance. By building a model that predicts performance (in this case photoelectrochemical power generation of a solar fuels photoanode) from materials parameters (in this case composition and Raman signal), subsequent analysis of gradients in the trained model reveals key data relationships that are not readily identified by human inspection or traditional statistical analyses. Human interpretation of these key relationships produces the desired fundamental understanding, demonstrating a framework in which machine learning accelerates data interpretation by leveraging the expertize of the human scientist. We also demonstrate the use of neural network gradient analysis to automate prediction of the directions in parameter space, such as the addition of specific alloying elements, that may increase performance by moving beyond the confines of existing data.

36 MATERIALS SCIENCE↗

Grooved electrodes for high-power-density fuel cells

Proton exchange membrane fuel cells (PEMFCs) are leading candidates to decarbonize the transport sector, but widespread deployment will require improvements in lifetime, fuel economy and cost. Here we present the grooved electrode, an alternative electrode structure that enhances PEMFC performance and durability by coupling high ionomer (ion-conducting binder) content for improved H + transport with grooves for rapid O 2 transport. Grooved electrodes provide up to 50% higher performance than state-of-the-art conventional electrodes under standard operating conditions. Fuel cell diagnostics combined with multiphysics modelling demonstrate that grooved electrodes provide facile O 2 transport despite their high ionomer content, enabling improved reaction rate uniformity. Grooved electrodes also provide improved durability, with less performance loss after carbon corrosion compared with baseline electrodes. Machine learning analysis demonstrates the potential to further optimize grooved structures for next-generation PEMFCs with enhanced performance and durability, enabling smaller and cheaper fuel cell stacks with higher fuel efficiency.

25 ENERGY STORAGE↗

Fuel-Flexible Combustion System for Refinery and Chemical Plant Process Heaters

This project culminated in the demonstration of a full-scale industrial burner which allows a broad range of “opportunity” gaseous fuels to be cost-effectively and efficiently utilized while generating minimal emissions of criteria air pollutants. The burner is capable of maintaining a stable flame when the fuel composition changes rapidly. This enhanced stability will contribute significantly to improving the safety and reliability of burner operation in manufacturing sites. Process heating in the refining and chemicals sectors is the primary application for this burner. The refining and chemical sectors account for more than 40% of total industrial natural gas use. Prior to the completion of this project, an enabling technology did not exist that would allow these energy-intensive industries to take full advantage of opportunity fuels and thereby reduce their natural gas consumption. Opportunity gaseous fuels include biogas (from animal and agricultural wastes, wastewater plants, and landfills) as well as syngas (from the gasification of biomass, municipal solid wastes, construction wastes, and refinery residuals). The primary challenge to using gaseous opportunity fuels is that their composition and combustion performance differ significantly from those of conventional fuels such as natural gas and refinery fuel gas. An effective fuel-flexible burner must accept fuels that range widely in quality and change in composition over time, often rapidly. In Phase 1 of this project, the team applied computational fluid dynamics analysis to optimize the prototype burner’s aerodynamic, combustion, heat transfer, and emissions performance. In Phase 2, full-scale testing and refinement of two prototype burners were conducted in test furnaces at Zeeco’s offices in Broken Arrow, OK. These tests demonstrated that the full range of conventional and opportunity fuels could be utilized by the project’s burner while achieving robust flame stability and very low levels of air pollutant emissions. In Phase 3, the team retrofitted three fuel-flexible burners into a fired heater at a Shell plant and demonstrated the project’s technology over a 6-month period. The project burners performed well during this period. They remain in commercial service at the Shell plant. Through this work, an improved understanding of flame stabilization mechanisms was gained. Also, methods for accommodating a wide range of fuel compositions were developed. This knowledge facilitated the commercialization of a new generation of burners that are suitable for the fuels of the future.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Characterization of Particulate Matter Emissions from Heavy-Duty Partially Premixed Compression Ignition with Gasoline-Range Fuels

In this study, the compression ratio of a commercial 15L heavy-duty diesel engine was lowered and a split injection strategy was developed to promote partially premixed compression ignition (PPCI) combustion. Various low reactivity gasoline-range fuels were compared with ultra-low-sulfur diesel fuel (ULSD) for steady-state engine performance and emissions. Specially, particulate matter (PM) emissions were examined for their mass, size and number concentrations, and further characterized by organic/elemental carbon analysis, chemical speciation and thermogravimetric analysis. As more fuel-efficient PPCI combustion was promoted, a slight reduction in fuel consumption was observed for all gasoline-range fuels, which also had higher heating values than ULSD. Since mixing-controlled combustion dominated the latter part of the combustion process, hydrocarbon (HC) and carbon monoxide (CO) emissions were only slightly increased with the gasoline-range fuels. In contrast, soot emissions were significantly reduced with the gasoline-range fuels, including a ~70% reduction in micro soot sensor measurements and a >50% reduction in smoke meter measurements. All gasoline-range fuel PM samples were also found to contain higher amount of volatile species and organic carbon fractions compared to ULSD PM samples as measured by thermogravimetric and EC-OC analyses. Various partially oxidized HC species and nitrophenolic compounds were also detected by TDP-GC-MS and CE-MS techniques, which implied that more pronounced PPCI combustion occurred with the gasoline-range fuels. As a whole similar PM oxidation behavior was observed despite the differences in reactivity and chemical properties of the fuels, even though there may be some significant impacts under certain operating conditions.

33 ADVANCED PROPULSION SYSTEMS↗