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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Status of Glenn-HT Code Applications to Complex Cooling Geometries

The Glenn-HT code is a 3D Navier-Stokes solver that has been used and validated for a variety of convective heat transfer problems associated with turbine flows. These flows have included tip clearance, simplified internal cooling, and film cooling. The multi-block capability of the code makes it particularly useful for the complex geometries of such flows. One of the goals of the UEET program is to reduce turbine cooling flow while increasing turbine inlet temperature. The Glenn-HT code gives researchers a tool to analyze the flow within the very complicated geometries associated with actual cooled turbine designs. Through these analyses and their comparison with experimental data, it is hoped to extend the applicability of the Glenn-HT code for use as a tool to improve turbine cooling designs to meet UEET goals.

Heidmann, James↗
NASA NTRS1987

Local heat/mass transfer and pressure drop in a two-pass rib-roughened channel for turbine airfoil cooling

The heat transfer characteristics of turbulent air flow in a multipass channel were studied via the naphthalene sublimation technique. The naphthalene-coated test section, consisting of two straight, square channels joined by a 180 deg turn, resembled the internal cooling passages of gas turbine airfoils. The top and bottom surfaces of the test channel were roughened by rib turbulators. The rib height-to-hydraulic diameter ratio (e/D) were 0.063 and 0.094, and the rib pitch-to-height ratio (P/e) were 10 and 20. The local heat/mass transfer coefficients on the roughened top wall and on the smooth divider and side walls of the test channel were determined for three Reynolds numbers of 15, 30, and 60, thousand, and for three angles of attack (alpha) of 90, 60, and 45 deg. Results showed that the local Sherwood numbers on the ribbed walls were 1.5 to 6.5 times those for a fully developed flow in a smooth square duct. The average ribbed-wall Sherwood numbers were 2.5 to 3.5 times higher than the fully developed values, depending on the rib angle of attack and the Reynolds number. The results also indicated that, before the turn, the heat/mass transfer coefficients in the cases of alpha = 60 and 45 deg were higher than those in the case of alpha=90 deg. However, after the turn, the heat/mass transfer coefficients in the oblique-rib cases were lower than those in the transverse rib case. Correlations for the average Sherwood number ratios for individual channel surfaces and for the overall Sherwood number ratios are reported. Correlations for the fully developed friction factors and for the loss coefficients are also provided.

Han, J. C.↗
NASA NTRS1998

A Thermal Physiological Comparison of Two HazMat Protective Ensembles With and Without Active Convective Cooling

Wearing impermeable garments for hazardous materials clean up can often present a health and safety problem for the wearer. Even short duration clean up activities can produce heat stress injuries in hazardous materials workers. It was hypothesized that an internal cooling system might increase worker productivity and decrease likelihood of heat stress injuries in typical HazMat operations. Two HazMat protective ensembles were compared during treadmill exercise. The different ensembles were created using two different suits: a Trelleborg VPS suit representative of current HazMat suits and a prototype suit developed by NASA engineers. The two life support systems used were a current technology Interspiro Spirolite breathing apparatus and a liquid air breathing system that also provided convective cooling. Twelve local members of a HazMat team served as test subjects. They were fully instrumented to allow a complete physiological comparison of their thermal responses to the different ensembles. Results showed that cooling from the liquid air system significantly decreased thermal stress. The results of the subjective evaluations of new design features in the prototype suit were also highly favorable. Incorporation of these new design features could lead to significant operational advantages in the future.

Williamson, Rebecca↗
NASA NTRS1984

Altitude testing of a flight weight, self-cooled, 2D thrust vectoring exhaust nozzle

The Augmented Deflector Exhaust Nozzle (ADEN) was tested in PSL-3 at NASA-Lewis Research Center using an F404 engine. The ADEN is a flight weight Single Expansion Ramp Nozzle with thrust vectoring, an internal cooling system utilizing the available engine fan flow, and a variable area throat controlled by the engine control system. Test conditions included dry and max A/B operation at nozzle pressure ratios from 2.0 to 15.0. High nozzle pressure loading was simulated to verify structural integrity at near maximum design pressure. Nozzle settings covered the full range in throat area and + or - 15 deg deflection angle. Test results demonstrated expected aerodynamic performance, cooling system effectiveness, control system stability, and mechanical integrity.

Wooten, W. H.↗
DOE OSTI2025

Optimal Design and Operation of Intensified Absorbers with 3D-Printed Packing for Solvent-Based CO 2 Capture

Many potential solvent-based carbon capture processes suffer from a high heat of absorption of CO 2 that adversely affects the thermodynamic driving force. While interstage coolers are often used for removing a portion of the generated heat by removing the solvent or a portion of the solvent from a stage and cooling and returning it back to the absorber, they can be placed only at discrete locations in the tower. This work investigates intensified absorbers with 3D-printed packing that includes an internal cooler and therefore can be potentially used for maximizing the operational efficiency of the absorbers for CO 2 capture. The intensified absorber is modeled by using a generic, first-principles, equation-oriented absorber column model. Since the placement of these intensified packings would cause a loss of area/volume used for mass transfer, optimization of the proposed intensified absorber is performed by optimally selecting the locations at which to place these devices and designing them such that the trade-off due to the addition of the heat removal area and the resulting loss in the mass transfer area is accounted for. Results show that optimally placed and designed intensified packings can lead to a significant increase in the capture efficiency of the process in comparison to a similar column with no internal cooling. It is also observed that by optimally placing and designing intensified packings, the lean solvent flow rate to the absorber can be decreased, and the CO 2 lean loading can be increased while still maintaining the same capture efficiency. These process changes can lead to a substantial reduction in the cost of capture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1978

Stress analysis study in cooled radial inflow turbine

With increased turbine inlet temperatures, numerical methods of thermal and stress analysis are becoming more valuable in the design of air-cooled turbines. This paper presents a study of the stresses associated with different cooling patterns in a radial inflow turbine rotor. The finite element method is used in the stress calculations taking into consideration centrifugal, thermal and aerodynamic loading. The effects of temperature distribution and the presence of internal cooling passages are discussed.

Hamed, A.↗
NASA NTRS2008

Intelligent Engine Systems: Thermal Management and Advanced Cooling

The objective is to provide turbine-cooling technologies to meet Propulsion 21 goals related to engine fuel burn, emissions, safety, and reliability. Specifically, the GE Aviation (GEA) Advanced Turbine Cooling and Thermal Management program seeks to develop advanced cooling and flow distribution methods for HP turbines, while achieving a substantial reduction in total cooling flow and assuring acceptable turbine component safety and reliability. Enhanced cooling techniques, such as fluidic devices, controlled-vortex cooling, and directed impingement jets, offer the opportunity to incorporate both active and passive schemes. Coolant heat transfer enhancement also can be achieved from advanced designs that incorporate multi-disciplinary optimization of external film and internal cooling passage geometry.

Bergholz, Robert↗
NASA NTRS1976

Development of explosive welding procedures to fabricate channeled nozzle structures

Research was conducted to demonstrate the feasibility of fabricating a large contoured structure with complex internal channeling by explosive welding procedures. Structures or nozzles of this nature for wind tunnel applications were designed. Such nozzles vary widely in their complexity. However, in their simplest form, they consist of a grooved base section to which a cover sheet is attached to form a series of internal cooling passages. The cover sheet attachment can be accomplished in various ways: fusion welding, brazing, and diffusion welding. The cover sheet has also been electroformed in place. Of these fabrication methods, brazing has proved most successful in producing nozzles with complex contoured surfaces and a multiplicity of internal channels.

Pattee, H. E.↗
DOE OSTI2022

Review of liquid desiccant air dehumidification systems coupled with heat pump: System configurations, component design, and performance

Vapor Compression Systems (VCS) are the most common air conditioning technology. VCS cool the air to its dew point temperature (overcooling) to remove water vapor in the air through condensation and then reheats the air back to the comfort temperature for direct use. The VCS process is inefficient due to overcooling and reheating. Liquid Desiccant Dehumidification (LDD) is a potentially energy-efficient air conditioning. LDD removes water vapor in the process air using liquid desiccant’s high-water affinity. It hybrids with sensible cooling to control temperature and humidity separately. The LD in the LDD becomes weak after dehumidification. The LDD needs additional heating to regenerate the weak Liquid Desiccant (LD) to a high concentration for dehumidification. Earlier versions of the LDD systems use highly concentrated liquid desiccant (large water removal capability) to dehumidify the air by only dealing with latent load. It leads to highly elevated temperatures above 60 °C of heat sources (combustion or electric resistance-based heating) for regeneration. The energy needed for the elevated temperature heat resource significantly reduces or demolishes the benefit of LDD systems. In the recent two decades, researchers have investigated a new configured LDD system that couples an LDD with a heat pump at both dehumidification and regeneration sides for better efficiency. The heat pump provides cooling (from the evaporator) for both dehumidification and sensible cooling and simultaneous heating from the condenser for regeneration. The highly integrated system (HP-LDD) with improved efficiency enables the LDD to operate at lower concentrations and temperatures in dehumidification and regeneration. This paper depicts the working principle behind HP-LDD and its heating and cooling requirements. It reviews the comparison between the HP-LDD systems and the conventional LDD systems regarding system configurations, component design, energy efficiency, and dehumidification performance characteristics. The main findings from the review include the preferred use of packed bed over membrane-based dehumidifiers, the use of internally cooled dehumidifiers enabled by the HP cooling capacity, the high dispersion of HP operation conditions, and the dependence of dehumidification performance on various dehumidifiers. Finally, an outlook for future research on HP-LDD strategies is presented based on the reviewed works and their limitations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1994

Miniature Convection Cooled Plug-type Heat Flux Gauges

Tests and analysis of a new miniature plug-type heat flux gauge configuration are described. This gauge can simultaneously measure heat flux on two opposed active surfaces when heat flux levels are equal to or greater than about 0.2 MW/m(sup 2). The performance of this dual active surface gauge was investigated over a wide transient and steady heat flux and temperature range. The tests were performed by radiatively heating the front surface with an argon arc lamp while the back surface was convection cooled with air. Accuracy is about +20 percent. The gauge is responsive to fast heat flux transients and is designed to withstand the high temperature (1300 K), high pressure (15 MPa), erosive and corrosive environments in modern engines. This gauge can be used to measure heat flux on the surfaces of internally cooled apparatus such as turbine blades and combustors used in jet propulsion systems and on the surfaces of hypersonic vehicles. Heat flux measurement accuracy is not compromised when design considerations call for various size gauges to be fabricated into alloys of various shapes and properties. Significant gauge temperature reductions (120 K), which can lead to potential gauge durability improvement, were obtained when the gauges were air-cooled by forced convection.

Liebert, Curt H.↗
DOE OSTI2024

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

Additive Manufacturing (AM), also known as 3D printing, has emerged as a manufacturing method that enables new design freedom for gas turbine engine manufacturers. However, the material selection for AM processable high-temperature super alloys is currently limited. Additionally, the heat transfer performance of AM enabled micro-cooling architectures is not yet well understood. Accordingly, in support of advanced manufacturing and engine performance development, Oak Ridge National Laboratory (ORNL)and Solar Turbines (Solar) conducted a multidisciplinary project to generate both AM super alloy material properties data and micro-channel performance data for two AM super alloys. The data supported the design and analysis of an internally cooled turbine hot section AM tip shoe component. This data was used to analytically predict the reduction in operating temperature of a gas turbine tip shoe. The work concluded that the cooling flow required to cool the tip shoe can be tuned to suit the efficiency improvements desired in an industrial gas turbine.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Unique Temperature Trend Pattern Associated With Internally Driven Global Cooling and Arctic Warming During 1980–2022

Abstract Diagnosing the role of internal variability over recent decades is critically important for both model validation and projections of future warming. Recent research suggests that for 1980–2022 internal variability manifested as Global Cooling and Arctic Warming (i‐GCAW), leading to enhanced Arctic Amplification (AA), and suppressed global warming over this period. Here we show that such an i‐GCAW is rare in CMIP6 large ensembles, but simulations that do produce similar i‐GCAW exhibit a unique and robust internally driven global surface air temperature (SAT) trend pattern. This unique SAT trend pattern features enhanced warming in the Barents and Kara Sea and cooling in the Tropical Eastern Pacific and Southern Ocean. Given that these features are imprinted in the observed record over recent decades, this work suggests that internal variability makes a crucial contribution to the discrepancy between observations and model‐simulated forced SAT trend patterns.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Towards directed energy deposition of metals using polymer-based supports: porosity of 316L stainless steel deposited on carbon-fiber-reinforced ABS

Directed energy deposition (DED) is increasingly valuable to many industries because of its high deposition rates relative to other metal additive manufacturing processes, but the design space of DED is limited. For instance, steep overhangs are difficult or impossible to manufacture. Polymer-based support structures could help address this challenge. The viability of DED on polymer composite substrates has begun to be explored, specifically with 316L stainless steel on carbon-fiber-reinforced ABS substrates. Monolithic metal components can be deposited on the polymer, but it was found that gas release during polymer degradation causes porosity due to gas entrapment in the metal. An interlayer cooling time was introduced to reduce polymer degradation and decrease the porosity due to gas entrapment, but this led to porosity from lack of fusion. The results of this work provide insight into process parameter selection and scan strategy development to enable the use of polymer support structures in blown-powder DED.

Kurfess, Rebecca↗
NASA NTRS1985

Thermophoretically enhanced mass transport rates to solid and transpiration-cooled walls across turbulent (law-of-the-wall) boundary layers

Convective-diffusion mass transfer rate predictions are made for both solid wall and transpiration-cooled 'law-of-the-wall' nonisothermal turbulent boundary layers (TBLs), including the mechanism of thermophoresis, i.e., small particle mass transport 'down a temperature gradient'. The present calculations are confined to low mass-loading situations but span the entire particle size range from vapor molecules to particles near the onset of inertial ('eddy') impaction. It is shown that, when Sc is much greater than 1, thermophoresis greatly increases particle deposition rates to internally cooled solid walls, but only partially offsets the appreciable reduction in deposition rates associated with dust-free gas-transpiration-cooled surfaces. Thus, efficient particle sampling from hot dusty gases can be carried out using transpiration 'shielded' probe surfaces.

Gokoglu, Suleyman A.↗
DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Cooling Rate Study of Nickel-Rich Material During Thermal Treatment and Quench

To investigate quench cracking that results from water quenching after heat treatment of binary and Ni-rich material, cooling rates of specimens were measured during quenching and hardness post-thermal treatment. For specific applications binary Ni-Ti is customarily thermally treated and quenched to attain desired mechanical properties and hardness. However, one problem emerging from this method is thermal cracking, either during the heat treatment process or during the specimen's application. This can result in material and equipment failure as well as financial losses. The objective of the study is to investigate the internal cooling rate of 60-NiTi during quenching and determine possible factors causing thermal cracking. Cubic (1 in.3) samples of both material were heat treated in air at 1000 deg C for 2 hrs and quenched in room temperature water using two methods: (1) dropped in the water and (2) agitated in the water. Hardness of the two fore-mentioned methods was measured post heat treatment. Results indicate that the quenching method had an effect on cooling rate during quenching but hardness was observed to be essentially the same through the thickness of the samples.

Thermal Crack↗
NASA NTRS1985

Safety considerations in the design of Spacelab refrigerator/freezer

A vapor compression refrigerator/freezer has been designed for Spacelab to conduct life sciences experiments. It is equipped with different safety features to eliminate all probable types of failures. The whole Freon loop is enclosed in a second containment so that any leakage of Freon can be contained. The unit is provided with an 'Emergency On' switch to actuate during backup mode which provides the spacecraft power directly to the compressor and the cooling fans while removing the power supply and all normal control elements from the circuit. During this mode, the compressor runs continuously when operating as a freezer (-22 C) and is controlled by a thermostat to cycle when operating as a refrigerator (4 C). It has a push button switch at the front panel to momentarily power the thermometer by a battery to monitor the inside temperature during an emergency. It has a door switch which shuts off the internal cooling fans when the door is opened. All the important critical performance data will be downlinked through a data connector to monitor during mission.

Hye, A.↗
NASA NTRSDate not supplied

Investigation of Additive Manufactured GRCop-42 Alloy Developed by Directed Energy Deposition Methods

GRCop is an alloy family constructed of copper, chromium, and niobium and was developed by NASA for high heat flux applications. GRCop-alloys were specifically formulated for the requirements in channel-cooled main combustion chambers allowing for repeat use in high heat flux environments[1]. GRCop-84 was evolved using additive manufacturing techniques under a NASA development program. To further increase thermal conductivity while maintaining material strength characteristics, the percentage of alloying elements were cut in half and GRCop-42 was developed. In recent years, NASA has successfully additively manufactured GRCop-42 with comparable material characteristics to extrudedGRCop-42 using a Laser Powder Bed Fusion (L-PBF) process. Benefits of this process include fabrication of intricate internal cooling channels as well as a decrease in manufacturing time. However, there are some large disadvantages in using this process. The nature of the powder bed process imposes a strict volume constraint as well as an excessive amount of material inventory required. A Directed Energy Deposition (DED) process addresses these limitations while also speeding up the manufacturing process. With little data on how DED performs with GRCop-42, an investigation into the mechanical properties was conducted. More specifically, Blown Powder Directed Energy Deposition (BPD), was used to compare material properties to that of the L-PBF manufactured GRCop-42. The DED manufactured material was found to have less than 0.1% porosity. Tensile tests concluded that the DED manufactured GRCop-42 had lower tensile strengths at room temperature. The results point towards a process capable of producing fully dense parts capable of meeting mechanical strength requirements with some possible refinement of printing parameters.

GRCop-42↗