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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 1,081 records · Page 60
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with no apparent wear. Material physical properties and the hot firing tests are reviewed.

Holmes, Richard↗
DOE OSTI2016

Evaluation of Knock Behavior for Natural Gas - Gasoline Blends in a Light Duty Spark Ignited Engine

The compression ratio is a strong lever to increase the efficiency of an internal combustion engine. However, among others, it is limited by the knock resistance of the fuel used. Natural gas shows a higher knock resistance compared to gasoline, which makes it very attractive for use in internal combustion engines. The current paper describes the knock behavior of two gasoline fuels, and specific incylinder blend ratios with one of the gasoline fuels and natural gas. The engine used for these investigations is a single cylinder research engine for light duty application which is equipped with two separate fuel systems. Both fuels can be used simultaneously which allows for gasoline to be injected into the intake port and natural gas to be injected directly into the cylinder to overcome the power density loss usually connected with port fuel injection of natural gas. Adding natural gas at wide open throttle helps to reduce knock mitigating measures and increases the efficiency and power density compared to the other gasoline type fuels with lower knock resistance. The used methods, knock intensity and number of pressure waves, do not show significant differences in knock behavior for the natural gas - gasoline blends compared to the gasoline type fuels. A knock integral was used to describe the knock onset location of the fuels tested. Two different approaches were used to determine the experimental knock onset and were compared to the knock onset delivered by the knock integral (chemical knock onset). The gasoline type fuels show good agreement between chemical and experimental knock onset. However, the natural gas -gasoline blends show higher discrepancies comparing chemical and experimental knock onset.

Advanced Combustion Concept↗
DOE OSTI2019

Modular design: Implementing proven engineering principles in biotechnology

Modular design resides at the foundation of contemporary engineering, enabling rapid, efficient, and reproducible construction and maintenance of complex systems across applications. Remarkably, modularity has recently been discovered as a governing principle in natural biological systems from genes to proteins to complex networks within a cell and organism communities. The convergent knowledge of natural and engineered modular systems provides a key to drive modern biotechnology to address emergent challenges associated with health, food, energy, and the environment. Here, we first present the theory and application of modular design in traditional engineering fields. We further discuss the significance and impact of modular architectures on systems biology and biotechnology. Next, we focus on the very recent theoretical and experimental advances in modular cell engineering that seeks to enable rapid and systematic development of microbial catalysts capable of efficiently synthesizing a large space of useful chemicals. We conclude with an outlook towards theoretical and practical opportunities for a more systematic and effective application of modular engineering in biotechnology.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

Environmental degradation of high-temperature protective coatings for ceramic-matrix composites in gas-turbine engines

Abstract The need for higher efficiencies and performance in gas-turbine engines that propel aircraft in the air, and generate electricity on land, is pushing the operating temperatures of the engines to unprecedented levels. Replacing some of the current hot-section metallic components with ceramic-matrix composites (CMCs) is making that possible. A high-temperature ceramic coatings system, that includes environmental-barrier coatings (EBCs), are needed to protect CMCs. However, these coatings undergo degradation in the highly hostile environment of the gas-turbine engine consisting of a combination of high gas temperatures, pressures, and velocities. In addition, there is the ubiquitous presence of steam (a combustion by-product) and occasional ingestion of calcia-magnesia-aluminosilicates (CMASs) in the form of dust, sand, or ash from the environment. Steam can cause corrosion of EBCs, and the molten CMAS deposits can react with the EBCs resulting in their failure. This article provides a perspective on the understanding of these degradation mechanisms, and possible approaches, guided by that understanding, for mitigating the degradation. An outlook on the future challenges and opportunities is presented.

Padture, Nitin P. (ORCID:0000000166228559)↗
NASA NTRS1921

Performance of a Liberty 12 airplane engine

In cooperation with the Engineering Division of the Air Service of the United States Army, a Liberty-12 engine has been tested at the Bureau of Standards. The program of tests was planned to yield that information considered most important in determining the value of the engine for aviation. Full power runs were made at the ground, at 25,000 feet, and at several intermediate altitudes. To determine the mechanical efficiency of the engine, friction horsepower was measured at the ground and at 15,000 feet. As a basis for predicting engine performance with a propeller, a series of tests was made in which the dynamometer load and engine throttle were adjusted at each speed to simulate the engine load which would be imposed at that speed by a propeller operating under normal full load at 1,700 r.p.m. Among the quantities calculated from the test measurements are: brake horsepower; break mean effective pressure; fuel consumption; mixture ratio; mechanical, thermal, and volumetric efficiency; and the percentage of the heat in the fuel appearing in the jacket water and in the exhaust. Jacket water temperature, oil temperature, manifold pressure, etc., are recorded to show the conditions under which the test was made.

Sparrow, S W↗
DOE OSTI2021

Lepidopteran mevalonate pathway optimization in Escherichia coli efficiently produces isoprenol analogs for next-generation biofuels

Terpenes constitute the largest class of natural products with over 55,000 compounds with versatile applications including drugs and biofuels. Introducing structural modifications to terpenes through metabolic engineering is an efficient and sustainable way to improve their properties. Here, in this study, we report the optimization of the lepidopteran mevalonate (LMVA) pathway towards the efficient production of isopentenyl pyrophosphate (IPP) analogs as terpene precursors. First, we linked the LMVA pathway to NudB, a promiscuous phosphatase, resulting in the production of the six-carbon analog of 3-methyl-3-buten-1-ol (isoprenol), 3-ethyl-3-buten-1-ol (C6-isoprenol). Using C6-isoprenol as the final product, we then engineered the LMVA pathway by redirecting its upstream portion from a thiolase-dependent pathway to a beta-oxidation pathway. The beta-oxidation LMVA pathway transforms valeric acid, a platform chemical that can be produced from biomass, into C6-isoprenol at a titer of 110.3 mg/L, improved from 5.5 mg/L by the thiolase LMVA pathway, which used propionic acid as a feedstock. Knockout of the E. coli endogenous thiolase genes further improved the C6-isoprenol titer to 390 mg/L, implying efficient production of homo isopentenyl pyrophosphate (HIPP). The beta-oxidation LMVA-NudB pathway also converts butanoic acid and hexanoic acid into isoprenol and isoprenol’s seven-carbon analog, 3-propyl-3-buten-1-ol (C7-isoprenol), respectively, suggesting the beta-oxidation LMVA pathway produces IPP and C7-IPP from the corresponding fatty acids. Fuel property tests revealed the longer chain isoprenol analogs have lower water solubilities, similar or higher energy densities, and comparable research octane number (RON) boosting effects to isopentenols. This work not only optimizes the LMVA pathway, setting the basis for homoterpene biosynthesis to expand terpene chemical space, but provides an efficient pathway to produce isoprenol analogs as next-generation biofuels from sustainable feedstocks.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

Efficiency and Emissions Characteristics of an HCCI Engine Fueled by Primary Reference Fuels

Here, this article investigates the effects of various primary reference fuel (PRF) blends, compression ratios, and intake temperatures on the thermodynamics and performance of homogeneous charge compression ignition (HCCI) combustion in a Cooperative Fuels Research (CFR) engine. Combustion phasing was kept constant at a CA50 phasing of 5° after top dead center (aTDC) and the equivalence ratio was kept constant at 0.3. Meanwhile, the compression ratio varied from 8:1 to 15:1 as the PRF blends ranged from pure n-heptane to nearly pure isooctane. The intake temperature was used to match CA50 phasing. In addition to the experimental results, a GT-Power model was constructed to simulate the experimental engine and the model was validated against the experimental data. The GT-Power model and simulation results were used to help analyze the energy flows and thermodynamic conditions tested in the experiment. The results indicate that an increase of compression ratio causes higher thermal efficiency and fuel conversion efficiency; however, at the same compression ratio, an increase in PRF number results in lower efficiency due to the required increase in intake temperature and the associated decrease in charge density. While the efficiency does increase with compression ratio, the results show that the effect of increased expansion work is partially offset by higher heat transfer losses and lower ratios of specific heats at higher compression ratios. The results indicate that the maximum pressure rise rate (MPRR) in HCCI significantly increases with compression ratio. Combustion efficiency shows a strong trend with peak temperature regardless of the PRF number or compression ratio, indicating that the CO-to-CO2 conversion is independent of the parent fuel chemistry in the case of the PRFs, whereas the unburned hydrocarbon emissions showed the opposite trend, depending mostly on the parent fuel’s autoignition tendency.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1998

Flight Testing the Linear Aerospike SR-71 Experiment (LASRE)

The design of the next generation of space access vehicles has led to a unique flight test that blends the space and flight research worlds. The new space vehicle designs, such as the X-33 vehicle and Reusable Launch Vehicle (RLV), are powered by linear aerospike rocket engines. Conceived of in the 1960's, these aerospike engines have yet to be flown, and many questions remain regarding aerospike engine performance and efficiency in flight. To provide some of these data before flying on the X-33 vehicle and the RLV, a spacecraft rocket engine has been flight-tested atop the NASA SR-71 aircraft as the Linear Aerospike SR-71 Experiment (LASRE). A 20 percent-scale, semispan model of the X-33 vehicle, the aerospike engine, and all the required fuel and oxidizer tanks and propellant feed systems have been mounted atop the SR-71 airplane for this experiment. A major technical objective of the LASRE flight test is to obtain installed-engine performance flight data for comparison to wind-tunnel results and for the development of computational fluid dynamics-based design methodologies. The ultimate goal of firing the aerospike rocket engine in flight is still forthcoming. An extensive design and development phase of the experiment hardware has been completed, including approximately 40 ground tests. Five flights of the LASRE and firing the rocket engine using inert liquid nitrogen and helium in place of liquid oxygen and hydrogen have been successfully completed.

Stephen Corda↗
NASA NTRS1984

Holographic aids for internal combustion engine flow studies

Worldwide interest in improving the fuel efficiency of internal combustion (I.C.) engines has sparked research efforts designed to learn more about the flow processes of these engines. The flow fields must be understood prior to fuel injection in order to design efficient valves, piston geometries, and fuel injectors. Knowledge of the flow field is also necessary to determine the heat transfer to combustion chamber surfaces. Computational codes can predict velocity and turbulence patterns, but experimental verification is mandatory to justify their basic assumptions. Due to their nonintrusive nature, optical methods are ideally suited to provide the necessary velocity verification data. Optical sytems such as Schlieren photography, laser velocimetry, and illuminated particle visualization are used in I.C. engines, and now their versatility is improved by employing holography. These holographically enhanced optical techniques are described with emphasis on their applications in I.C. engines.

Regan, C.↗
NASA NTRSDate not supplied

High-Fidelity Modeling Approach for Coupling Thermal, Fluid, and Neutronic Analysis in an NTP Engine

Nuclear thermal propulsion (NTP), with its increased efficiency compared to traditional rocket engines, is a potentially enabling technology for space missions of higher complexity, such as delivering heavy machinery or crew to the moon or other planets. Thus, exploring modeling approaches that can effectively couple the thermal, fluid, and neutronic behaviors of NTP reactors is essential to mitigate cost and schedule challenges with hardware development. This paper details one such approach which utilizes Cardinal to unify reactor physics analysis performed using OpenMC, heat transfer analysis performed using the MOOSE framework, and thermal hydraulic analysis performed using the MOOSE Thermal Hydraulic Module. This approach is demonstrated with a proof of concept that focuses on a legacy reactor geometry from the historic NERVA program. This preliminary model found an overprediction in, when compared to the reference data, axial power peaking and the temperatures of both solids and fluids by roughly 20%. It is clear, however, that the model conserved a number of broad trends, and a few model refinements should reduce the observed error. This approach has definite merit and should enable the production of informative results for more modern NTP systems. This work is a first step in creating a transient reactor model that can be updated across a sequence of time steps based on continually fluctuating, time-dependent boundary conditions.

Nuclear Thermal Propulsion↗
NASA NTRS1921

Performance of a 300-horsepower Hispano-Suiza airplane engine

The National Bureau of Standards tested a 300-horsepower Hispano-Suiza engine to determine the characteristic performance of the engine at various altitudes. The engine was operated at the ground, at 25,000 feet, and at intermediate altitudes, both at full loads similar to those that would be imposed upon the engine at various speeds by a propeller whose normal full-load speed was 1,800 r.p.m. Friction horsepower also was determined in order that the mechanical efficiency of the engine might be calculated. From the test data there were computed the brake horsepower, brake mean effective pressure, specific fuel consumption, mixture ratio, jacket loss, exhaust loss, and thermal, mechanical, and volumetric efficiencies. A record of jacket water temperatures, oil temperatures, manifold pressures, etc., shows the conditions under which the test was made.

Sparrow, S W↗
DOE OSTI2018

Medium-Duty Diesel Combustion

Faster combustion improves the efficiency of a diesel engine, and in medium-duty diesel engines, interactions between the fuel sprays and the piston bowl walls play a key role in determining heat-release rates. Stepped-lip pistons can promote the formation of vortices that are correlated with faster, more efficient heat-release, but this behavior is primarily observed for late injection timings at which the engine is not operating at its peak efficiency. The objectives of this part of the project are to explain the physical mechanisms responsible for this phenomenon, to identify measures that may enhance vortex formation, and to quantify the extent to which these measures may improve the engine's thermal efficiency.

42 ENGINEERING↗
NASA NTRS1998

General Aviation Light Aircraft Propulsion: From the 1940's to the Next Century

Current general aviation light aircraft are powered by engines that were originally designed in the 1940's. This paper gives a brief history of light aircraft engine development, explaining why the air-cooled, horizontally opposed piston engine became the dominant engine for this class of aircraft. Current engines are fairly efficient, and their designs have been updated through the years, but their basic design and operational characteristics are archaic in comparison to modem engine designs, such as those used in the automotive industry. There have been some innovative engine developments, but in general they have not been commercially successful. This paper gives some insight into the reasons for this lack of success. There is now renewed interest in developing modem propulsion systems for light aircraft, in the fore-front of which is NASA's General Aviation Propulsion (GAP) program. This paper gives an overview of the engines being developed in the GAP program, what they will mean to the general aviation community, and why NASA and its industry partners believe that these new engine developments will bring about a new era in general aviation light aircraft.

Burkardt, Leo A.↗
NASA NTRS1999

Robust Low Cost Aerospike/RLV Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. At the same time, fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of a shrinking NASA budget. In recent years, combustion chambers of equivalent size to the Aerospike chamber have been fabricated at NASA-Marshall Space Flight Center (MSFC) using innovative, relatively low-cost, vacuum-plasma-spray (VPS) techniques. Typically, such combustion chambers are made of the copper alloy NARloy-Z. However, current research and development conducted by NASA-Lewis Research Center (LeRC) has identified a Cu-8Cr-4Nb alloy which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. In fact, researchers at NASA-LeRC have demonstrated that powder metallurgy (P/M) Cu-8Cr-4Nb exhibits better mechanical properties at 1,200 F than NARloy-Z does at 1,000 F. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost, VPS process to deposit Cu-8Cr-4Nb with mechanical properties that match or exceed those of P/M Cu-8Cr-4Nb. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the hot wall of the liner during the VPS process. Tensile properties of Cu-8Cr-4Nb material produced by VPS are reviewed and compared to material produced previously by extrusion. VPS formed combustion chamber liners have also been prepared and will be reported on following scheduled hot firing tests at NASA-Lewis.

Holmes, Richard↗
NASA NTRS2005

Damage Accumulation and Failure of Plasma-Sprayed Thermal Barrier Coatings under Thermal Gradient Cyclic Conditions

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. A fundamental understanding of the sintering and thermal cycling induced delamination of thermal barrier coating systems under engine-like heat flux conditions will potentially help to improve the coating temperature capability. In this study, a test approach is established to emphasize the real-time monitoring and assessment of the coating thermal conductivity, which can initially increase under the steady-state high temperature thermal gradient test due to coating sintering, and later decrease under the thermal gradient cyclic test due to coating cracking and delamination. Thermal conductivity prediction models have been established for a ZrO2-(7- 8wt%)Y2O3 model coating system in terms of heat flux, time, and testing temperatures. The coating delamination accumulation is then assessed based on the observed thermal conductivity response under the combined steady-state and cyclic thermal gradient tests. The coating thermal gradient cycling associated delaminations and failure mechanisms under simulated engine heat-flux conditions will be discussed in conjunction with the coating sintering and fracture testing results.

Zhu, Dongming↗
NASA NTRSDate not supplied

Model Predictive Control Study for an Electrified Turbofan Engine

A control sensitivity study is conducted for electrified aircraft propulsion concepts using a publicly available turbofan engine simulation. A Proportional-Integral (PI) controller serves as a baseline for comparison against an advanced Model Predictive Control (MPC) approach. MPC is used in the control scheme to allow for subsystem coordination of engine and electric power loads. The electrified turbofan engine includes electric machines to augment the amount of torque being applied to the spools of the engine during transient phases of operation. Power augmentation allows for energy to be stored or exhausted in a manner that increases the fuel efficiency of the engine, reducing aircraft emissions and noise. The study compares the fan speed, high pressure compressor stall margin, and low pressure compressor stall margin against the baseline PI control system, an MPC system without electric machines, and an MPC system with electric machines. The MPC system with electric machines is optimized using the sample time, control horizon and prediction horizon. The MPC design provided a stable damped response as desired and allowed operability margins to be maintained

Electrified Aircraft Propulsion↗
NASA NTRS1976

Study of small turbofan engines applicable to single-engine light airplanes

The design, efficiency and cost factors are investigated for application of turbofan propulsion engines to single engine, general aviation light airplanes. A companion study of a hypothetical engine family of a thrust range suitable to such aircraft and having a high degree of commonality of design features and parts is presented. Future turbofan powered light airplanes can have a lower fuel consumption, lower weight, reduced airframe maintenance requirements and improved engine overhaul periods as compared to current piston engined powered airplanes. Achievement of compliance with noise and chemical emission regulations is expected without impairing performance, operating cost or safety.

Merrill, G. L.↗
DOE OSTI2023

Development and testing of residential micro-CHP powered by opposed piston engine (CRADA Final Report)

A micro–combined heat and power (mCHP) prototype powered by innovative opposed piston engine technology was developed to simultaneously provide electricity and heat to residential or light commercial buildings. The mCHP prototype targeted at residential applications includes an opposed-piston four-stroke (OP4S) engine, generator, rectifier, inverter, battery energy storage system, 52 gal water tank, and application accessories for hot water supply and space heating. The OP4S engine can use renewable or regular natural gas, as well as hydrogen, to generate mechanical power and waste heat in form of hot coolant and exhaust gas simultaneously. The waste heat is recovered and stored in the water tank and can be used as a regular hot water supply and/or for space heating application. The tests show that the mCHP prototype enabled power outputs in the range of 3.2 –7.4 kW with up to 26.4% of AC electricity efficiency and up to 93.1% of the overall mCHP efficiency under stoichiometric combustion modes λ=~1.0. The mCHP was also run under lean combustion mode conditions at λ=~1.3. The lean mode operation enables more than 30% improvement in electrical energy efficiency. The maximum AC efficiency of the lean combustion mode attained was 35.2%, with the engine efficiency is approaching 40%. The exceptional electrical efficiency breaks the typical upper boundary of 30% for ICE-based mCHP. The engine exhaust temperatures in the lean modes are substantially less than in the stoichiometric modes. Moreover, the lean cases achieve high overall mCHP efficiencies: the overall mCHP efficiencies are all greater than 93%. Considering the mCHP prototype can achieve low-cost, flexible matching of thermal and electrical loads through reducing the complexity of distribution and installation, and high efficiency the novel technology will promote mCHP acceptance in the US residential and light commercial markets.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗