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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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96 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated tempera-tures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple) trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A baseline CFD model is defined and its accuracy established to be comparable to (and which usually exceeds) the accuracy of existing HTC (heat-transfer correlation) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled), generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Carbon and Hydrocarbon Particle Seeding in Air-Breathing Rotating Detonation Engine

Within the power generation community, the rotating detonation engine (RDE) is only growing in popularity with its increased performance, simple mechanism, and operation. Although significant testing is underway to characterize the RDE for integration with conventional gas turbines, this entire system is still at a relatively low technology readiness level. In the midst of RDE research, there is an initiative to understand solid particle seeding effects in the detonation performance. Under investigation at the University of Central Florida is a Department of Energy (DOE) 15.24 cm (6 in.) RDE, with a solid particle seeder in parallel with its H2 and air flow lines. Previous work on this system involved carbon particle detonation; however, the tested particles were taken one step further to include more sustainable, greener hydrocarbon particles. Testing of powdered sugar, peanut flour, and cornstarch, along with previous carbon black tests have shown not only successful detonability, but a noticeable effect on the detonation wave dynamics. Side-by-side with a particle burning model being developed, an operational map can be determined for the hydrocarbon particles particularly, which can be tuned with the local flow conditions to achieve peak operability while replacing fuels with sustainable alternatives that could even be grown.

Engineering↗
DOE OSTI2024

High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation

This report summarizes the work performed by University of California San Diego (UCSD) – Honeywell Aerospace (Honeywell) team for the U.S. Department of Energy/Advanced Research Projects Agency-Energy (DOE/ARPA-E) under Phase 1 (April 2021 – October 2023) project, Cooperative Agreement DE-AR0001347 entitled “High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation”. The main objective of this project is to develop and demonstrate an energy storage and power generation (ESPG) system operating on bio liquid natural gas (LNG) for electric aviation applications. The ESPG system concept in this project is a fuel cell, battery, and gas turbine hybrid system that incorporates an innovative solid oxide fuel cell (SOFC) technology. This SOFC technology has two main novel elements: (i) a lightweight and compact stack architecture that consists of cells and cell modules in electrical parallel and series connections (the module design) and (ii) exceptionally high performance, direct methane thin-film cells on porous substrate made by sputtering deposition process. This fuel cell has the specific power and volumetric power density suitable for electric aviation applications. Based on the current status of the SOFC technology, the Phase 1 work focused on the following activities: (i) ESPG System Modeling – to design and optimize an aircraft SOFC-based ESPG system concept that met the performance, weight and cost targets; (ii) Cell Material Development and Scaleup – to demonstrate scalability of the sputtering process for manufacture of thin-film SOFC cells of practical sizes, confirm the exceptional performance of sputtered cells, improve cell stability and durability for operation with hydrogen and methane fuel, and develop a suitable electrically conducting porous substrate to replace the current non-conducting ceramic substrate; (iii) Stack Development – to design and manufacture stack components for the stack architecture, evaluate and select a suitable sealant, and build and operate multi-cell stacks to demonstrate stack operation, and (iv) Technology to Market – to develop business models and commercialization plans, conduct various market and technology analysis and estimate SOFC and ESPG system costs.

25 ENERGY STORAGE↗
DOE OSTI2025

Reducing NOx Emissions in Ammonia Combustors

Ammonia continues to attract growing interest as a carbonneutral replacement fuel, motivating numerous research efforts toward understanding fundamental ammonia combustion characteristics. A major challenge for the use of ammonia is the development of combustor technologies for mitigating potentially high NOx emissions from the fuel-bound nitrogen chemical pathways to acceptable levels. Our work focuses on a staged RQL combustor architecture for minimizing the NOx emission levels through burning fuel-rich in the primary stage to formcombustion products containing significant levels of hydrogen in addition to nitrogen and water with minimal NOx formation. The subsequent quench and burnout stages of the combustor must then quickly burn residual hydrogen with flame-temperatures moderated by nitrogen and water forming in the first stage. Chemical Reactor Network modeling was used to understand and identify optimal stoichiometry and residence times in each stage for minimizing NOx emissions and to quantify pressure and temperature effects. Reducing the overall NOx emissions requires relatively long residence times in the primary stage to achieve near equilibrium NO levels due to kinetically controlling processes. For conditions relevant to gas turbines (e.g., 30 atm), our work indicates that NOx emissions below 20 ppm are theoretically achievable in a staged RQL combustor architecture. However, these emission predictions significantly depend on the accuracies of currently available chemical kinetic mechanisms which have not been extensively validated under elevated pressure and temperature conditions relevant to gas turbines.

10 SYNTHETIC FUELS↗
DOE OSTI2021

Ocean Energy Systems Wave Energy Modeling Task 10.4: Numerical Modeling of a Fixed Oscillating Water Column

This paper reports on an ongoing international effort to establish guidelines for numerical modeling of wave energy converters, initiated by the International Energy Agency Technology Collaboration Program for Ocean Energy Systems. Initial results for point absorbers were presented in previous work, and here we present results for a breakwater-mounted Oscillating Water Column (OWC) device. The experimental model is at scale 1:4 relative to a full-scale installation in a water depth of 12.8 m. The power-extracting air turbine is modeled by an orifice plate of 1–2% of the internal chamber surface area. Measurements of chamber surface elevation, air flow through the orifice, and pressure difference across the orifice are compared with numerical calculations using both weakly-nonlinear potential flow theory and computational fluid dynamics. Both compressible- and incompressible-flow models are considered, and the effects of air compressibility are found to have a significant influence on the motion of the internal chamber surface. Recommendations are made for reducing uncertainties in future experimental campaigns, which are critical to enable firm conclusions to be drawn about the relative accuracy of the numerical models. It is well-known that boundary element method solutions of the linear potential flow problem (e.g., WAMIT) are singular at infinite frequency when panels are placed directly on the free surface. This is problematic for time-domain solutions where the value of the added mass matrix at infinite frequency is critical, especially for OWC chambers, which are modeled by zero-mass elements on the free surface. A straightforward rational procedure is described to replace ad-hoc solutions to this problem that have been proposed in the literature.

16 TIDAL AND WAVE POWER↗