Results for “surface planarization” — Page 56

NASA NTRS2008

Forebody and Inlet Design for the HIFiRE 2 Flight Test

A forebody and inlet have been designed for the HIFiRE 2 scramjet flight test. The test will explore the operating, performance, and stability characteristics of a simple hydrocarbon-fueled scramjet combustor as it transitions from dual-mode to scramjet-mode operation and during supersonic combustion at Mach 8+ flight conditions. Requirements for the compression system were derived from inlet starting and combustor inflow requirements as well as physical size constraints. The design process is described. A planar, fixed geometry, mixed compression concept was used to produce laterally uniform flow at the inlet entrance and a conservative amount of internal contraction with respect to inlet starting. A grid sensitivity study was performed so that important flow physics caused by three-dimensional shock boundary layer interactions could be captured with confidence. Results from low Mach number operability studies, nominal trajectory cases, and high dynamic pressure heat load cases are discussed. The forebody and inlet solutions provide information for on-going combustor calculations, mass capture across the trajectory for fuel system design, and surface heating rates for thermal/structural analysis. The design has a one freestream Mach number margin for inlet starting, exceeds the high Mach number combustor entrance pressure requirement, produces high quality flow at the inlet exit for all Mach numbers and vehicle attitudes in the design space, and fits inside the booster shroud.

Ferlemann, Paul G.↗

DOE OSTI2024

Inkjet-printed SnO x as an effective electron transport layer for planar perovskite solar cells and the effect of Cu doping

Inkjet printing is a more sustainable and scalable fabrication method than spin coating for producing perovskite solar cells (PSCs). Although spin-coated SnO 2 has been intensively studied as an effective electron transport layer (ETL) for PSCs, inkjet-printed SnO 2 ETLs have not been widely reported. Here, we fabricated inkjet-printed, solution-processed SnO x ETLs for planar PSCs. A champion efficiency of 17.55% was achieved for the cell using a low-temperature processed SnO x ETL. The low-temperature SnO x exhibited an amorphous structure and outperformed high-temperature crystalline SnO 2 . The improved performance was attributed to enhanced charge extraction and transport and suppressed charge recombination at ETL/perovskite interfaces, which originated from enhanced electrical and optical properties of SnO x , improved perovskite film quality, and well-matched energy level alignment between the SnO x ETL and the perovskite layer. Furthermore, SnO x was doped with Cu. Cu doping increased surface oxygen defects and upshifted energy levels of SnO x , leading to reduced device performance. A tunable hysteresis was observed for PSCs with Cu-doped SnO x ETLs, decreasing at first and turning into inverted hysteresis afterwards with increasing Cu doping level. This tunable hysteresis was related to the interplay between charge/ion accumulation and recombination at ETL/perovskite interfaces in the case of electron extraction barriers.

14 SOLAR ENERGY↗

NASA NTRS2016

Influence of Stationary Crossflow Modulation on Secondary Instability

A likely scenario for swept wing transition on subsonic aircraft with natural laminar flow involves the breakdown of stationary crossflow vortices via high frequency secondary instability. A majority of the prior research on this secondary instability has focused on crossflow vortices with a single dominant spanwise wavelength. This paper investigates the effects of the spanwise modulation of stationary crossflow vortices at a specified wavelength by a subharmonic stationary mode. Secondary instability of the modulated crossflow pattern is studied using planar, partial-differential-equation based eigenvalue analysis. Computations reveal that weak modulation by the first subharmonic of the input stationary mode leads to mode splitting that is particularly obvious for Y-type secondary modes that are driven by the wall-normal shear of the basic state. Thus, for each Y mode corresponding to the fundamental wavelength of results in unmodulated train of crossflow vortices, the modulated flow supports a pair of secondary modes with somewhat different amplification rates. The mode splitting phenomenon suggests that a more complex stationary modulation such as that induced by natural surface roughness would yield a considerably richer spectrum of secondary instability modes. Even modest levels of subharmonic modulation are shown to have a strong effect on the overall amplification of secondary disturbances, particularly the Z-modes driven by the spanwise shear of the basic state. Preliminary computations related to the nonlinear breakdown of these secondary disturbances provide interesting insights into the process of crossflow transition in the presence of the first subharmonic of the dominant stationary vortex.

Vortex structure↗

DOE OSTI2020

Magnetic order and fluctuations in the quasi-two-dimensional planar magnet Sr( Co 1-x Ni x ) 2 As 2

We use neutron scattering to investigate spin excitations in Sr ( Co 1 - x Ni x ) 2 As 2 , which has a c -axis incommensurate helical structure of the two-dimensional (2D) in-plane ferromagnetic (FM) ordered layers for 0.013 ≤ x ≤ 0.25 . By comparing the wave vector and energy dependent spin excitations in helical ordered Sr ( Co 0.9 Ni 0.1 ) 2 As 2 and paramagnetic SrCo 2 As 2 , we find that Ni doping, while increasing lattice disorder in Sr ( Co 1 - x Ni x ) 2 As 2 , enhances quasi-2D FM spin fluctuations. However, our band structure calculations within the combined density functional theory and dynamic mean field theory ( DFT + DMFT ) failed to generate a correct incommensurate wave vector for the observed helical order from nested Fermi surfaces. Furthermore, since transport measurements reveal increased in-plane and c -axis electrical resistivity with increasing Ni doping and associated lattice disorder, we conclude that the helical magnetic order in Sr ( Co 1 - x Ni x ) 2 As 2 may arise from a quantum order-by-disorder mechanism through the itinerant electron mediated Ruderman-Kittel-Kasuya-Yosida (RKKY) interactions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Theoretical study of the CO 2 –O 2 van der Waals complex: potential energy surface and applications

A four-dimensional-potential energy surface (4D-PES) of the atmospherically relevant carbon dioxide–oxygen molecule (CO 2 –O 2 ) van der Waals complex is mapped using the ab initio explicitly correlated coupled cluster method with single, double, and perturbative triple excitations (UCCSD(T)-F12b), and extrapolation to the complete basis set (CBS) limit using the cc-pVTZ-F12/cc-pVQZ-F12 bases and the l –3 formula. An analytic representation of the 4D-PES was fitted using the method of interpolating moving least squares (IMLS). These calculations predict that the most stable configuration of CO 2 –O 2 complex corresponds to a planar slipped-parallel structure with a binding energy of V ~ –243 cm –1 . Another isomer is found on the PES, corresponding to a non-planar cross-shaped structure, with V ~ –218 cm –1 . The transition structure connecting the two minima is found at V ~ –211 cm –1 . We also performed comparisons with some CO 2 –X van der Waals complexes. Moreover, we provide a SAPT analysis of this molecular system. Then, we discuss the complexation induced shifts of CO 2 and O 2 . Afterwards, this new 4D-PES is employed to compute the second virial coefficient including temperature dependence. A comparison between quantities obtained in our calculations and those from experiments found close agreement attesting to the high quality of the PES and to the importance of considering a full description of the anisotropic potential for the derivation of thermophysical properties of CO 2 –O 2 mixtures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Layer-by-layer growth of graphene oxide multilayers using robust interlayer linking chemistry. 2 Zr–bissulfates

We report on the facile layer-by-layer growth of graphene oxide sulfate (GO-S) multilayer structures. The layers are bonded to a modified planar silica support using Zr 4+ ions. Optical ellipsometry shows step-by-step layer growth with layer thickness consistent with that expected from molecular mechanics calculations. The reaction to form Zr–bissulfate linkages is facile, with multistep layer deposition occurring within six to ten minutes per layer. The GO-S layers can be deposited directly on GO-S underlayer(s) or interlayer spacers can be incorporated to control the spacing with GO-S layers. X-ray photoelectron spectroscopy (XPS) data provides information on the density of the sulfonated groups present at the graphene oxide surface and on the Zr : S ratio. This is the first report we are aware of that demonstrates robust layer-by-layer growth of graphene oxide structures.

Graphene oxide↗

DOE OSTI2019

Effects of turbulent flow regime on perforated plate stabilized piloted lean premixed flames

An experimental study of the effects of turbulent flow regime on the flame structure is conducted by using perforated-plate-stabilized, hydrogen-piloted, lean premixed methane/air turbulent flames. The underlying turbulent flow field was investigated using two-dimensional three-component particle imaging velocimetry (2D3C-PIV) with two perforated plates of different blockage ratios. The flow data allowed a separation of the turbulent flow regime into axial velocity stream dominated and vortex dominated flows. A plate with 62% blockage ratio was used to establish the stream-dominated flow regime and another with 86% blockage ratio was used to establish the vortex-dominated flow regime. OH laser-induced fluorescence was used to study the effects of the turbulent flow regime on the mean progress variable, flame brush thickness, flame surface density, and global consumption speed. In comparison with the stream-dominated flow, the vortex-dominated flow makes a wider and shorter flame. Also, the vortex-dominated flow has a thicker horizontal flame brush and a thinner longitudinal flame brush. Especially, the spatial variation of the horizontal flame brush thickness for the vortex-dominated flow does not follow the turbulent diffusion theory. The vortex-dominated flow shows a relatively constant flame surface density and the stream-dominated flow shows a decreasing flame surface density along the streamwise direction. The flame surface density for the vortex-dominated flow is higher than the one for the stream-dominated flow. Lastly, the vortex-dominated turbulent flow shows a much higher consumption speed in comparison with that of the stream-dominated turbulent flow with identical velocity fluctuation levels.

42 ENGINEERING↗

DOE OSTI2019

PTT System Performance Evaluation in 3-D Imaging of AM Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for non-destructive evaluation (NDE) either during or post manufacturing. Known material flaws in AM include low density regions consisting of nonsintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. This study investigates the capability of PTT in imaging several AM structures fabricated from Inconel 718 (IN718) feedstock. The AM structures have complex geometry, but do not have calibrated internal defects. The objective is to determine PTT settings, such as the total integration time, for imaging of representative AM structures. A new FLIR X8500sc IR camera with higher spatial resolution (1280x1024 at 181Hz frame rate) was integrated into the PTT laboratory setup. Software tools were developed to ensure compatibility of new camera files with legacy effusivity reconstruction codes. The new camera was used to obtain 3-D reconstructions of IN718 nozzle plate and a particle filter plate. The results demonstrate the capability of PTT in 3- D imaging of complex geometry AM structures. Further, increased resolution imaging is achieved compared to prior results using older FLIR SC4000 IR camera. In addition, preliminary studies were conducted on developing image processing algorithms for automated detection of flaws. Initial demonstrations are shown for segmentation of PTT images of flat bottom hole (FBH) specimens. Imaging of FBH specimens was described in a prior report. Intermediate results demonstrated in this report will be developed further in detection of flaws in AM specimens.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRSDate not supplied

Transition Modeling Based on the Dual N-factor Method for the CRM-NLF Wind Tunnel Configuration

The dual N-factor method is used to model the boundary-layer transition over the common research model with natural laminar flow (CRM-NLF) aircraft configuration. The flow conditions match selected test conditions from a wind tunnel experiment in the National Transonic Facility at the NASA Langley Research Center. The paper presents a systematic methodology for transition prediction in the presence of a dual shock system and extends the prior capability for iteratively coupled computational fluid dynamics (CFD) predictions to incorporate three-dimensional, transonic wings. The method employs stability computations based on the linear parabolized stability equations (PSE), along with a dual N-factor criterion. The iterative process begins with the fully turbulent Reynolds-averaged-Navier-Stokes (RANS) mean flow solution. For the first iteration, a mean flow solution is calculated with an imposed transition front that aligns with the shock front from the fully turbulent solution. Subsequently, stability computations are performed along a set of streamlines across the wing to calculate the amplification of planar Tollmien-Schlichting (TS) and stationary crossflow (CF) modes. The transition criterion based on the dual N-factor method is used to infer the updated transition front and the process is successively repeated until convergence of the solution. Within three iterations, the predicted fronts for angles of attack of 1.45, 1.98, 2.46 and 2.94 degrees and a mean-aerodynamic-chord Reynolds number equal to 15 million, approach visual convergence in most regions of the studied cases, and the resulting predictions are in good agreement with the transition fronts deduced from measurements of temperature-sensitive paint. Even though surface pressure measurements based on fully-turbulent flow agree well with the measured pressure coefficient distributions, strong viscous-inviscid interaction effects cause significant shifts in the shock locations based on the imposed transition front, underscoring the intrusive nature of static pressure measurements using surface mounted ports on the CRM-NLF configuration.

Boundary Layer Transition↗

DOE OSTI2019

First Annual Report on Pulsed Thermal Tomography Nondestructive Evaluation of Additively Manufactured Reactor Materials and Components: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. This report provides results of preliminary performance evaluation of PTT capability in detection of flaws in metallic structures, as well imaging complex geometry AM structures. Performance of PTT was investigated through modeling and experiments, Computer models of PTT were developed using COMSOL Heat Transfer module. Defects were modeled as cylindrical flat bottom holes (FBH), which is a common model of calibrated material flaws in thermal tomography experiments. Materials considered in this study include stainless steel 316 (SS316), stainless steel 304 (SS304), and Inconel 718. Theoretical analyses were conducted to validate inversion of simulated PTT data with COMSOL for a plate. Subsequently, 3D reconstructions were performed on COMSOL simulations for FBH, revealing a decrease in spatial resolution over depth due to thermal diffusion. The results of this study show that the performance of the inversion algorithm for detecting smaller defects depends strongly on the depth of the defect as well as the incident heat flux. The size of detectable defect was estimated by fitting a Gaussian function to surface temperature profile. The criteria for detectability was taken as 20mK noise equivalent temperature difference (NETD), which is currently the sensitivity limit of high-performance infrared cameras. It was determined through computer simulations that the smallest detectable FBH in SS316 has a 50µm diameter and is located 0.5mm below the plate surface. Preliminary experimental studies were performed to evaluate PTT performance in detecting calibrated flaws using metallic specimens with AM defects simulated as drilled-in FBH’s. High strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The diameters of FBH’s varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanical drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. Finally, PTT capability in imaging several AM structures fabricated from Inconel 718 (IN718) powder feedstock was investigated. The AM structures have complex geometry, but do not have calibrated internal defects. The objective is to determine PTT settings, such as the total integration time, for imaging of representative AM structures. A new FLIR X8500sc IR camera with higher spatial resolution (1280x1024 at 181Hz frame rate) was integrated into the PTT laboratory setup. Software tools were developed to ensure compatibility of new camera files with legacy effusivity reconstruction codes. The new camera was used to obtain 3-D reconstructions of AM IN718 nozzle plate and a particle filter plate. It was shown that PTT can scan through 2/3in-thick Inconel 718 plates in approximately 15s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages. The results demonstrate the capability of PTT in 3-D imaging of complex geometry AM structures. Intermediate results demonstrated in this report will be developed further to investigate detection of flaws in AM specimens.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

PTT System Design and Data Analysis for Improved Performance: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for non-destructive evaluation (NDE) either during or post manufacturing. Known material flaws in AM include low density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusively using a unique inversion algorithm developed at Argonne. This study investigates the limits of PTT capability in detection of defects in metallic plates using COMSOL numerical modeling of heat transfer. Defects are modeled as cylindrical flat bottom holes (FBH), which is a common model of calibrated material flaws in thermal tomography experiments. Materials considered in this study include stainless steel 316 (SS316), stainless steel 304 (SS304), and Inconel 718. Theoretical analyses were conducted to validate inversion of simulated PTT data with COMSOL for a plate. Subsequently, 3D reconstructions were performed on COMSOL simulations for FBH, revealing a decrease in spatial resolution over depth due to thermal diffusion. The results of this study show that the performance of the inversion algorithm for detecting smaller defects depends strongly on the depth of the defect as well as the incident heat flux. The size of detectable defect was estimated by fitting a Gaussian function to surface temperature profile. The criteria for detectability was taken as 20mK noise equivalent temperature difference (NETD), which is currently the sensitivity limit of high-performance infrared cameras. It was determined through computer simulations that the smallest detectable FBH in SS316 has a 50µm diameter and is located 0.5mm below the plate surface.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1982

A simple method to compute the change in earth-atmosphere radiative balance due to a stratospheric aerosol layer

A computer code was developed in terms of a three-layer model for the earth-atmosphere system, using a two-stream approximation for the troposphere and stratosphere. The analysis was limited to variable atmosphere loading by solar radiation over an unperturbed section of the atmosphere. The scattering atmosphere above a Lambertian ground layer was considered in order to derive the planar albedo and the spherical albedo. Attention was given to the influence of the aerosol optical thickness in the stratosphere, the single scattering albedo and asymmetry factor, and the sublayer albedo. Calculations were performed of the zonal albedo and the planetary radiation balance, taking into account a stratospheric aerosol layer containing H2SO4 droplets and volcanic ash. The resulting ground temperature disturbance was computed using a Budyko (1969) climate model. Local decreases in the albedo in the summer were observed in high latitudes, implying a heating effect of the aerosol. An accompanying energy loss of 23-27 W/sq m was projected, which translates to surface temperature decreases of either 1.1 and 0.45 C, respectively, for background and volcanic aerosols.

Lenoble, J.↗

NASA NTRS1987

Exact image method for Gaussian beam problems involving a planar interface

Exact image method, recently introduced for the solution of electromagnetic field problems involving sources above a planar interface or two homogeneous media, is shown to be valid also for sources located in complex space, which makes its application possible for Gaussian beam analysis. It is demonstrated that the Goos-Hanchen shift and the angular shift of a TE polarized beam are correctly given as asymptotic results by the exact reflection image theory. Also, the apparent image location giving the correct Gaussian beam transmitted through the interface is obtained as another asymptotic check. The present theory makes it possible to calculate the exact coupling from the Gaussian beam to the reflected and refracted beams, as well as to the surface wave.

Lindell, I. V.↗

NASA NTRS1993

Wind-tunnel investigation of aerodynamic efficiency of three planar elliptical wings with curvature of quarter-chord line

Three planar, untwisted wings with the same elliptical chord distribution but with different curvatures of the quarter-chord line were tested in the Langley 8-Foot Transonic Pressure Tunnel (8-ft TPT) and the Langley 7- by 10-Foot High-Speed Tunnel (7 x 10 HST). A fourth wing with a rectangular planform and the same projected area and span was also tested. Force and moment measurements from the 8-ft TPT tests are presented for Mach numbers from 0.3 to 0.5 and angles of attack from -4 degrees to 7 degrees. Sketches of the oil-flow patterns on the upper surfaces of the wings and some force and moment measurements from the 7 x 10 HST tests are presented at a Mach number of 0.5. Increasing the curvature of the quarter-chord line makes the angle of zero lift more negative but has little effect on the drag coefficient at zero lift. The changes in lift-curve slope and in the Oswald efficiency factor with the change in curvature of the quarter-chord line (wingtip location) indicate that the elliptical wing with the unswept quarter-chord line has the lowest lifting efficiency and the elliptical wing with the unswept trailing edge has the highest lifting efficiency; the crescent-shaped planform wing has an efficiency in between.

Mineck, Raymond E.↗

NASA NTRS1993

Petrography of shock features in the 1953 Manson 2-A drill core

Drilling of Nx core in late 1953 into an anomalous zone of disturbed rocks northwest of Manson, Iowa disclosed presence of extensive breccias including crystalline rocks brought to the surface from depths of 4 km or more. Hole 2-A penetrated breccias dominated by leucocratic igneous and metamorphic lithologies, later interpreted to be part of a general ringed peak complex within a 35 km wide impact structure produced about 65 Ma ago. Proof of this origin was given in 1966 by NMS through recognition of shock metamorphic features in 2-A materials during a cursory examination of samples provided by R.A. Hoppin, University of Iowa. A detailed study of this material now underway has revealed that most breccia clasts in 2-A show abundant and varied evidence of shock damage, including extensive planar deformation features (PDF) in quartz, K-feldspar, plagioclase, and a pyroxene and varying degrees of isotropization and incipient melting in feldspars.

Short, N. M.↗

NASA NTRS1994

Planar varactor frequency multiplier devices with blocking barrier

The invention relates to planar varactor frequency multiplier devices with a heterojunction blocking barrier for near millimeter wave radiation of moderate power from a fundamental input wave. The space charge limitation of the submillimeter frequency multiplier devices of the BIN(sup +) type is overcome by a diode structure comprising an n(sup +) doped layer of semiconductor material functioning as a low resistance back contact, a layer of semiconductor material with n-type doping functioning as a drift region grown on the back contact layer, a delta doping sheet forming a positive charge at the interface of the drift region layer with a barrier layer, and a surface metal contact. The layers thus formed on an n(sup +) doped layer may be divided into two isolated back-to-back BNN(sup +) diodes by separately depositing two surface metal contacts. By repeating the sequence of the drift region layer and the barrier layer with the delta doping sheet at the interfaces between the drift and barrier layers, a plurality of stacked diodes is formed. The novelty of the invention resides in providing n-type semiconductor material for the drift region in a GaAs/AlGaAs structure, and in stacking a plurality of such BNN(sup +) diodes stacked for greater output power with and connected back-to-back with the n(sup +) GaAs layer as an internal back contact and separate metal contact over an AlGaAs barrier layer on top of each stack.

Lieneweg, Udo↗

NASA NTRS2014

Development and Experimental Evaluation of Passive Fuel Cell Thermal Control

To provide uniform cooling for a fuel cell stack, a cooling plate concept was evaluated. This concept utilized thin cooling plates to extract heat from the interior of a fuel cell stack and move this heat to a cooling manifold where it can be transferred to an external cooling fluid. The advantages of this cooling approach include a reduced number of ancillary components and the ability to directly utilize an external cooling fluid loop for cooling the fuel cell stack. A number of different types of cooling plates and manifolds were developed. The cooling plates consisted of two main types; a plate based on thermopyrolytic graphite (TPG) and a planar (or flat plate) heat pipe. The plates, along with solid metal control samples, were tested for both thermal and electrical conductivity. To transfer heat from the cooling plates to the cooling fluid, a number of manifold designs utilizing various materials were devised, constructed, and tested. A key aspect of the manifold was that it had to be electrically nonconductive so it would not short out the fuel cell stack during operation. Different manifold and cooling plate configurations were tested in a vacuum chamber to minimize convective heat losses. Cooling plates were placed in the grooves within the manifolds and heated with surface-mounted electric pad heaters. The plate temperature and its thermal distribution were recorded for all tested combinations of manifold cooling flow rates and heater power loads. This testing simulated the performance of the cooling plates and manifold within an operational fuel cell stack. Different types of control valves and control schemes were tested and evaluated based on their ability to maintain a constant temperature of the cooling plates. The control valves regulated the cooling fluid flow through the manifold, thereby controlling the heat flow to the cooling fluid. Through this work, a cooling plate and manifold system was developed that could maintain the cooling plates within a minimal temperature band with negligible thermal gradients over power profiles that would be experienced within an operating fuel cell stack.

Fuel Cells↗

NASA NTRSDate not supplied

Preliminary Measurements on the BOLT Geometry in the Supersonic Low Disturbance Tunnel

Experiments were performed in the Mach 3.5 Supersonic Low Disturbance Tunnel on the BOundary-Layer Transition (BOLT) geometry. The goal of this campaign was to assess changes to the transition front by varying the freestream noise and the model surface quality. The model was printed of polycarbonate and is 30% scale of the flight geometry. It was tested under noisy and quiet conditions at different streamwise positions in the tunnel and was also tested before and after improvements were made to the model surface through sanding and gap reduction. Pitch and yaw angles were nominally zero. The model surface temperature was measured using infrared thermography and thermocouples as the unit Reynolds number was swept from 4.75 – 15.8 × 10 6 m −1 . Boundary-layer transition was observed near the midspan of the model for unit Reynolds numbers above 10×10 6 m −1 in quiet flow, while transition was already observed on the shoulders below 5×10 6 m −1 in noisy flow. The model surface enhancements improved the symmetry of the transition front for quiet flow but made only slight differences for noisy flow. In quiet flow, the impact of streamwise positioning on transition was more significant on the model shoulders compared to the central region. The difference in the shoulder heating was likely due to variation in noise radiated from the nozzle sidewalls. The total temperature and initial wall temperatures were near 300 K and 293 K, respectively, which generally resulted in negative convective heat-flux values into the model. Hot-wire anemometry was also utilized to characterize the freestream and to conduct a planar survey near the base of the model for the 7.92 × 10 6 m −1 quiet condition. The survey captured the thickening of the boundary layer at the centerline and the vortical nature of the flow outboard of it. Spectral analysis of the mass-flux fluctuations near the midspan demonstrates that the boundary layer is laminar and suggests that the thick boundary layer caused the relatively warm centerline observed in the infrared images.

boundary layer transition↗