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DOE OSTI2023

The Role of Topography in Controlling Evapotranspiration Age

Abstract Evapotranspiration (ET) age is a key metric of water sustainability but a major unknown partly due to the extreme difficulty in modeling it. Groundwater is found to be important in ET age variations in small‐scale studies, yet our understanding is insufficient because groundwater systems are nested across scales. Here, we conducted GPU‐accelerated particle tracking with integrated hydrologic modeling to quantify the variations in ET age at a regional scale of ∼0.4 M km 2 . Simulation results reveal topography‐driven flow paths shaping the spatial and temporal patterns of ET age variations. On ridges, where root zone decoupling with deep subsurface storage, ET age is generally young, with seasonal variations dominated by meteorological conditions. In the valley bottom, ET age is generally old, with significant subseasonal variations caused by the convergence of subsurface flow paths. On hillslopes with water table depths ranging from 1 to 10 m, ET age shows strong seasonal variations caused by the connections with lateral groundwater regulated by ET demand. Our modeling approach provides insights into the basic linkages between ET age and topography at large scale. Our work highlights the perspective of multiscale studies of ET age, suggesting new field experiments to test these process connections and to determine if such linkages warrant inclusion in Earth System Models.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRSDate not supplied

Seeding Method for Velocimetry and Visualization of Supersonic Retropropulsion Nozzle Plumes

In the current work, the “Venturi seeder” method for nozzle plumes is improved and studied to determine suitability for particle image velocimetry. This seeding method involves independently pressurizing the primary flow path and a separate seed liquid reservoir, connecting them at the throat of a Venturi contraction upstream of the nozzle. The pressure differential at the throat causes the liquid to enter the nozzle channel where it is atomized into particles by strong shearing forces. This new seeding system was characterized by conducting a series of diagnostics using different exit nozzle pressure ratios and seed reservoir pressures. Shadowgraph imaging confirmed the nozzle plumes to be underexpanded jets. A particle sizing device determined that generated DEHS oil particles had median aerodynamic diameters of 0.67, 0.69, and 0.73 μm for seed liquid reservoir pressure supplies of 0.67, 0.60, and 0.93 MPa and primary flow path pressures of 0.67, 0.76, and 0.93 MPa measured downstream of the Venturi throat, respectively. These diameters were within the threshold for acceptable response time in typical gas flows (≤ 1 μm). PIV experiments were conducted on the nozzle plume for all presented cases; mean axial and transverse velocities appeared as expected for the underexpanded jet structure, including the Mach disk and re-acceleration regions. Additional sizing analysis based on the particle response times across the normal shock again showed particle diameters to be well less than 1 μm for all cases. The results suggest that this method is an inexpensive and relatively simple solution to the problem of seeding nozzle plumes. The method will be used in testing of supersonic retropropulsion models in the Unitary Plan Wind Tunnel at The NASA Langley Research Center in 2022.

particle image velocimetry↗

NASA NTRS2014

Turbulence Model Effects on RANS Simulations of the HIFiRE Flight 2 Ground Test Configurations

The Wind-US Reynolds-averaged Navier-Stokes solver was applied to the Hypersonic International Flight Research Experimentation (HIFiRE) Flight 2 scramjet ground test configuration. Two test points corresponding to flight Mach numbers of 5.9 and 8.9 were examined. The emphasis was examining turbulence model effects on the prediction of flow path pressures. Three variants of the Menter k-omega turbulence model family were investigated. These include the baseline (BSL) and shear stress transport (SST) as well as a modified SST model where the shear stress limiter was altered. Variations in the turbulent Schmidt number were also considered. Choice of turbulence model had a substantial effect on prediction of the flow path pressures. The BSL model produced the highest pressures and the SST model produced the lowest pressures. As expected, the settings for the turbulent Schmidt number also had significant effects on predicted pressures. Small values for the turbulent Schmidt number enabled more rapid mass transfer, faster combustion, and in turn higher flowpath pressures. Optimal settings for turbulence model and turbulent Schmidt number were found to be rather case dependent, as has been concluded in other scramjet investigations.

Georgiadis, Nicholas J.↗

DOE OSTI2024

Redesigning large-scale multimodal transit networks with shared autonomous mobility services

Here, this study addresses a large-scale multimodal transit network design problem, with Shared Autonomous Mobility Services (SAMS) as both transit feeders and an origin-to-destination mode. The framework captures spatial demand and modal characteristics, considers intermodal transfers and express services, determines transit infrastructure investment and path flows, and generates transit routes. A system-optimal multimodal transit network is designed with minimum total door-to-door generalized costs of users and operators, satisfying transit origin-destination demand within a pre-set infrastructure budget. Firstly, the geography, demand, and modes in each zone are characterized with continuous approximation. The decisions of network link investment and multimodal path flows in zonal connection optimization are formulated as a minimum-cost multi-commodity network flow (MCNF) problem and solved efficiently with a mixed-integer linear programming (MILP) solver. Subsequently, the route generation problem is solved by expanding the MCNF formulation to minimize intramodal transfers. The model is illustrated through a set of experiments with the Chicago network comprised of 50 zones and seven modes, under three scenarios. The computational results present savings in traveler journey time and operator cost demonstrating the potential benefits of collaboration between multimodal transit systems and SAMS.

Autonomous vehicles↗

DOE OSTI2023

Geoelectric Characterization of Hyporheic Exchange Flow in the Bedrock‐Lined Streambed of East Fork Poplar Creek, Oak Ridge, Tennessee

Abstract A multimethod geoelectric survey was implemented between January and March 2022 along a 220‐m long reach of the bedrock‐lined streambed of East Fork Poplar Creek in Oak Ridge, Tennessee to identify locations of surface‐water and groundwater exchange and characterize the subsurface flow paths that convey water between the stream and flood plain. A waterborne self‐potential (WaSP) survey was completed in January 2022 to measure the electric streaming‐potential field in the stream. Electric resistivity tomography (ERT) was performed in March 2022 on the flood plain adjacent to the WaSP survey reach to map the electric resistivity distribution and characterize the hydrogeology and subsurface flow paths that facilitate surface‐water and groundwater exchange in the bedrock‐lined stream. The combination of WaSP and ERT data support the qualitative interpretation that surface‐water and groundwater exchange likely occurs along fractures in outcropping bedrock and along two fault lines that intersect the limestone creek bed.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2016

Characterization of Carbon Dioxide Washout Measurement Techniques in the Mark-III Space Suit

Providing adequate carbon dioxide (CO2) washout is essential to the reduction of risk in performing suited operations. Long term CO2 exposure can lead to symptoms such as headache, lethargy, dizziness, and in severe cases can lead to unconsciousness and death. Thus maintaining adequate CO2 washout in both ground testing and during in flight EVAs is a requirement of current and future suit designs. It is necessary to understand the inspired CO2 of suit wearers such that future requirements for space suits appropriately address the risk of inadequate washout. Testing conducted by the EVA Physiology Laboratory at the NASA Johnson Space Center aimed to characterize a method for noninvasively measuring inspired oronasal CO2 under pressurized suited conditions in order to better inform requirements definition and verification techniques for future CO2 washout limits in space suits. Prior work conducted by the EPL examined several different wearable, respirator style, masks that could be used to sample air from the vicinity surround the nose and mouth of a suited test subject. Previously published studies utilized these masks, some being commercial products and some novel designs, to monitor CO2 under various exercise and flow conditions with mixed results for repeatability and/or consistency between subjects. Based on a meta-analysis of those studies it was decided to test a nasal cannula as it is a commercially available device that is placed directly in the flow path of the user as they breathe. A nasal cannula was used to sample air inhaled by the test subjects during both rest and exercise conditions. Eight subjects were tasked with walking on a treadmill or operating an arm ergometer to reach target metabolic rates of 1000, 2000, and 3000 BTU/hr. Suit pressure was maintained at 4.3 psid for all tests, with supply flow rates of 6, 4, and 2 actual cubic feet per minute depending on the test condition. Each test configuration was conducted twice with subjects breathing either through their nose only, or however they felt comfortable. By restricting breathing through a single orifice, we are able to more accurately define exactly what flow stream the sampled CO2 is taken from. Oronasal CO2 was monitored using real time infrared gas analyzers fed via sample tubes connected to the nasal cannula within the suit. Two additional sampling tubes were placed at the head and chin of the test subject, in an effort to capture CO2 concentrations across the entire flow stream of the Mark-III vent system (flow path is head to neck). Metabolic rate was calculated via the exhaust CO2 concentration and used to adjust subject workload on either the treadmill or arm ergometer until the target was reached. Forward work will aim to characterize the historically accepted minimum ppCO2 in suit during EVA by repeating this study in the Extravehicular Mobility Unit (EMU) space suit. This will help to define washout requirements for future suits, be they NASA (e.g. Z-2) or Commercial Crew designed. Additionally it is important to determine the functional consequences of CO2 exposure during EVA. Severe CO2 symptoms are a result of very high concentration, acute exposures. While long term, low concentration exposures have been shown to result in slight cognitive decline, symptoms resolve upon quickly returning to nominal concentrations and it remains unknown the impact that minor deficits in cognitive performance can have on EVA performance.

Norcross, J.↗

DOE OSTI2020

Mechanistic modeling of CO 2 well leakage in a generic abandoned well through a bridge plug cement-casing gap

Both known and unmapped plugged and abandoned wells are potential leakage pathways for CO 2 from geologic carbon sequestration (GCS) sites. Although many abandoned wells have cement bridge plugs installed to prevent leakage, the seal between the cement and the inner casing wall is subject to failure. In this study, we carried out detailed T2Well simulations of cases of sudden non-Darcy flow of CO 2 and brine leakage up the gap between a cement plug and the inner steel casing wall that becomes a fully connected flow path during the post-injection period. The goal of our study was two-fold: (1) to understand the dynamics, rates, and the characteristic temporal signals associated with the onset of leakage through various gap-aperture sizes, and (2) to suggest potential monitoring strategies based on the findings. Simulation results show that the leakage of CO 2 and brine upward is transient with interesting phase interference behavior. Time-dependent oscillatory flows with varying pressure, temperature, and flow rates of CO 2 and brine show strong dependence on gap aperture. Phase-change and decompression lead to very low temperatures at the top of the well for gap apertures larger than 4 mm suggesting that remote thermal monitoring at the ground surface may be an effective way of monitoring even if well locations are not known a priori. Pressure in the well is also indicative of CO 2 leakage. The temporal patterns of changing temperature and pressure may be useful diagnostic signals for leakage detection. Finally, these transient leakage signals may provide information on the cause of leakage and/or characteristics of the flow path that could inform effective remediation design and execution approaches.

58 GEOSCIENCES↗

NASA NTRS2009

Overview of the Turbine Based Combined Cycle Discipline

The NASA Fundamental Aeronautics Hypersonics project is focused on technologies for combined cycle, airbreathing propulsions systems to enable reusable launch systems for access to space. Turbine Based Combined Cycle (TBCC) propulsion systems offer specific impulse (Isp) improvements over rocket-based propulsion systems in the subsonic takeoff and return mission segments and offer improved safety. The potential to realize more aircraft-like operations with expanded launch site capability and reduced system maintenance are additional benefits. The most critical TBCC enabling technologies as identified in the National Aeronautics Institute (NAI) study were: 1) mode transition from the low speed propulsion system to the high speed propulsion system, 2) high Mach turbine engine development, 3) transonic aero-propulsion performance, 4) low-Mach-number dual-mode scramjet operation, 5) innovative 3-D flowpath concepts and 6) innovative turbine based combined cycle integration. To address several of these key TBCC challenges, NASA s Hypersonics project (TBCC Discipline) initiated an experimental mode transition task that includes an analytic research endeavor to assess the state-of-the-art of propulsion system performance and design codes. This initiative includes inlet fluid and turbine performance codes and engineering-level algorithms. This effort has been focused on the Combined Cycle Engine Large-Scale Inlet Mode Transition Experiment (CCE LIMX) which is a fully integrated TBCC propulsion system with flow path sizing consistent with previous NASA and DoD proposed Hypersonic experimental flight test plans. This experiment is being tested in the NASA-GRC 10 x 10 Supersonic Wind Tunnel (SWT) Facility. The goal of this activity is to address key hypersonic combined-cycle-engine issues: (1) dual integrated inlet operability and performance issues unstart constraints, distortion constraints, bleed requirements, controls, and operability margins, (2) mode-transition constraints imposed by the turbine and the ramjet/scramjet flow paths (imposed variable geometry requirements), (3) turbine engine transients (and associated time scales) during transition, (4) high-altitude turbine engine re-light, and (5) the operating constraints of a Mach 3-7 combustor (specific to the TBCC). The model will be tested in several test phases to develop a unique TBCC database to assess and validate design and analysis tools and address operability, integration, and interaction issues for this class of advanced propulsion systems. The test article and all support equipment is complete and available at the facility. The test article installation and facility build-up in preparation for the inlet performance and operability characterization is near completion and testing is planned to commence in FY11.

Thomas, Scott R.↗

NASA NTRSDate not supplied

Advanced Single Phase Thermal Radiator for Moon-to-Mars Exploration

Pumped loop radiators are commonly used to reject large amounts of heat associated with crewed systems. The State-of-the-Art (SOA) for crewed systems is represented by the International Space Station (ISS) External Heat Rejection System (HRS) Thermal Radiators. The ISS HRS utilizes a manifold design with many parallel flow paths coupled to thin face-sheets and low viscosity ammonia as the working fluid, which may not be preferred due to toxicity concerns. Although contemporary coolant choices provide lower freezing points, the current SOA design may not be well positioned to provide both sufficient heat transfer and manageable pressure drop due to very different fluid thermo-physical properties, including higher viscosities. The planned development of an advanced single phase, pumped loop thermal radiator utilizing a serpentine flow path with high thermally conductive face-sheets is presented herein.

In-Space Active Thermal Control↗

NASA NTRS2016

Digital Valve for High Pressure High Flow Applications

To address the challenges, which are involved with the development of flow control valves that can meet the requirements of deep oil wells such as high pressure, high flow rate, limited power and limited space, the authors have conceived a novel design configuration [1]. This design consists of a digitalized flow control valve with multipath and multistage pressure reduction structures. Specifically, the valve is configured as a set of parallel flow paths from the inlet to the outlet. A choke valve controls the total flow rate by digitally opening different paths or different combination of the paths. Each path is controlled by a poppet cap valve basically operated in on-off states. The number of flow states is 2N where N is the number of flow paths. To avoid erosion from sand in the oil and high speed flow, the seal area of the poppet cap valve is located at a distance from the flow inlet away from the high speed flow and the speed is controlled to stay below a predefined erosion safe limit. The path is a multistage structure composed of a set of serial nozzles-expansion chambers that equally distribute the total pressure drop to each stage. The pressure drop of each stage and, therefore, the flow speed at the nozzles and expansion chambers is controlled by the number of stages. The paths have relatively small cross section and could be relatively long for large number of stages and still fit in the strict annular space limit of a typical downhole region of an oil well. The paper will present the design configuration, analysis and preliminary test results.

downhole↗

NASA NTRS2017

Shape Memory Actuated Normally Open Permanent Isolation Valve

A valve assembly for an in-space propulsion system includes an inlet tube, an outlet tube, a valve body coupling the inlet tube to the outlet tube and defining a propellant flow path, a valve stem assembly disposed within the valve body, an actuator body coupled to the valve body, the valve stem assembly extending from an interior of the valve body to an interior of the actuator body, and an actuator assembly disposed within the actuator body and coupled to the valve stem assembly, the actuator assembly including a shape memory actuator member that when heated to a transition temperature is configured to enable the valve stem assembly to engage the outlet tube and seal the propellant flow path.

Ramspacher, Daniel J.↗

NASA NTRS2009

Advanced Computational and Experimental Techniques for Nacelle Liner Performance Evaluation

The Curved Duct Test Rig (CDTR) has been developed to investigate sound propagation through a duct of size comparable to the aft bypass duct of typical aircraft engines. The axial dimension of the bypass duct is often curved and this geometric characteristic is captured in the CDTR. The semiannular bypass duct is simulated by a rectangular test section in which the height corresponds to the circumferential dimension and the width corresponds to the radial dimension. The liner samples are perforate over honeycomb core and are installed on the side walls of the test section. The top and bottom surfaces of the test section are acoustically rigid to simulate a hard wall bifurcation or pylon. A unique feature of the CDTR is the control system that generates sound incident on the liner test section in specific modes. Uniform air flow, at ambient temperature and flow speed Mach 0.275, is introduced through the duct. Experiments to investigate configuration effects such as curvature along the flow path on the acoustic performance of a sample liner are performed in the CDTR and reported in this paper. Combinations of treated and acoustically rigid side walls are investigated. The scattering of modes of the incident wave, both by the curvature and by the asymmetry of wall treatment, is demonstrated in the experimental results. The effect that mode scattering has on total acoustic effectiveness of the liner treatment is also shown. Comparisons of measured liner attenuation with numerical results predicted by an analytic model based on the parabolic approximation to the convected Helmholtz equation are reported. The spectra of attenuation produced by the analytic model are similar to experimental results for both walls treated, straight and curved flow path, with plane wave and higher order modes incident. The numerical model is used to define the optimized resistance and reactance of a liner that significantly improves liner attenuation in the frequency range 1900-2400 Hz. A liner impedance descriptor is used to determine the liner parameters that achieve the optimum impedance.

Gerhold, Carl H.↗

DOE OSTI2020

Krypton-81 dating of the deep Continental Intercalaire aquifer with implications for chlorine-36 dating

Deep groundwater samples from the Continental Intercalaire (CI) aquifer in the Northern Tunisian Sahara have been analyzed for noble gases 3 He, 4 He, Ne and 81 Kr, and for 14 C to better constrain the groundwater residence time of this large transboundary aquifer. Its significant radiogenic 4 He content and background-level 14 C both indicate water older than a few tens of thousands of years. Distinct helium concentrations and Ne/He ratios suggest different groundwater flow paths through the Tozeur and Kebili regions. 81 Kr is applied for the first time on the CI aquifer, providing more direct evidence for the presence of old groundwater with 81 Kr/Kr ratios at 63% – 15% of the atmospheric value, corresponding to residence times of 150 – 630 ka. These newly obtained 81 Kr ages enable a re-evaluation of the previously reported data from the Tozeur region in order to better constrain the input values of 36 Cl/Cl and Cl. The initial 36 Cl/Cl ratio is found to be 4 – 6 times larger than previously assumed, and the initial Cl concentration 6 – 15 times smaller. The results of 81 Kr dating and the recalibrated 36 Cl dating define an eastward age progression across > 500 km of flow path from the Algerian to Tunisian sections. Here, this study exemplifies the utility of 81 Kr not only as an independent and conservative chronometer, but also as a supplemental measurement to better calibrate the parameters required for other age tracers, including cosmogenic 36 Cl and radiogenic 4 He.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Geochemical and microbial characteristics of seepage water and mineral precipitates in a radwaste disposal facility impacted by seawater intrusion and high alkalinity

The construction of an underground facility can dramatically change the quality, flow direction, and level of groundwater. It may also impact subsurface microbial composition and activity. Groundwater quality was monitored over eight years in two observational wells near an underground disposal facility on the east coast of South Korea. The results showed dramatic increases in dissolved ions such as O 2 , Na, Ca, Mg, and SO 4 during facility construction. Seepage water samples downgradient from the silos and tunnels, and precipitates deposited along the seepage water flow path were collected to determine the impact inside the disposal facility. X-ray analysis (powder X-ray diffraction (pXRD) and X-ray absorption fine structure (XAFS)) were used to characterize the mineral precipitates. Microbial community composition was determined by 16S rRNA gene sequencing. The seepage water composition was of two types: Ca-Cl and Ca-Na-HCO 3 . The ratio of Cl and δ 18 O showed that the Ca-Cl type seepage water was influenced by groundwater mixed with seawater ranging from 2.7% to 15.1%. Various sulfate-reducing bacteria were identified in the Ca-Cl type seepage water, exhibiting relatively high sulfate content from seawater intrusion. Samples from the Ca-Na-HCO 3 type seepage water had an extremely high pH (>10) and abundance of Hydrogenophaga. The precipitates observed along the flow path of the seepage water included calcite, ferrihydrite, green rust, and siderite, depending on seepage water chemistry and microbial activity. This study suggests that the construction of underground structures creates distinct, localized geochemical conditions (e.g., high alkalinity, high salinity, and oxic conditions), which may impact microbial communities. These biogeochemical changes may have undesirable large-scale impacts such as water pump clogging. Overall, an understanding of the process and long-term monitoring are essential to assess the safety of underground facilities.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Model Scripts for "Old-Aged Groundwater Contributes to Mountain Hillslope Hydrologic Dynamics"

The partitioning of water inputs between deep and shallow groundwater flow paths is a fundamental processes, yet is challenging to observe. Numerical models provide a valuable tool to further develop insights on these groundwater mixing processes. This repository contains scripts to run the ParFlow-CLM and EcoSLIM integrated hydrologic models along the Pumphouse Hillslope in the East River Watershed and associated python scripts to process model outputs. Files includes input decks for the associated models, python scripts, and text and css files to support the model runs and processing. The 2-D hillslope model simulates from 2000 to 2021 using transient forcing conditions from the publicly available NLDAS-2 dataset. We develop an ensemble of models with variable hydrogeologic and soil parameters. Model outputs from the ensemble of runs are compared to to water level observations at the PLM1 and PLM6 wells published at (https://data.ess-dive.lbl.gov/view/doi:10.15485/1866836) and groundwater mean ages published at (https://data.ess-dive.lbl.gov/datasets/doi:10.15485/1960042. The model results are used to evaluate hillslope water mass-balance transience and mixing dynamics between groundwater flow paths with young (<10 year) and old (>10 year) ages.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2014

Modeling of Commercial Turbofan Engine With Ice Crystal Ingestion: Follow-On

The occurrence of ice accretion within commercial high bypass aircraft turbine engines has been reported under certain atmospheric conditions. Engine anomalies have taken place at high altitudes that have been attributed to ice crystal ingestion, partially melting, and ice accretion on the compression system components. The result was degraded engine performance, and one or more of the following: loss of thrust control (roll back), compressor surge or stall, and flameout of the combustor. As ice crystals are ingested into the fan and low pressure compression system, the increase in air temperature causes a portion of the ice crystals to melt. It is hypothesized that this allows the ice-water mixture to cover the metal surfaces of the compressor stationary components which leads to ice accretion through evaporative cooling. Ice accretion causes a blockage which subsequently results in the deterioration in performance of the compressor and engine. The focus of this research is to apply an engine icing computational tool to simulate the flow through a turbofan engine and assess the risk of ice accretion. The tool is comprised of an engine system thermodynamic cycle code, a compressor flow analysis code, and an ice particle melt code that has the capability of determining the rate of sublimation, melting, and evaporation through the compressor flow path, without modeling the actual ice accretion. A commercial turbofan engine which has previously experienced icing events during operation in a high altitude ice crystal environment has been tested in the Propulsion Systems Laboratory (PSL) altitude test facility at NASA Glenn Research Center. The PSL has the capability to produce a continuous ice cloud which is ingested by the engine during operation over a range of altitude conditions. The PSL test results confirmed that there was ice accretion in the engine due to ice crystal ingestion, at the same simulated altitude operating conditions as experienced previously in flight. The computational tool was utilized to help guide a portion of the PSL testing, and was used to predict ice accretion could also occur at significantly lower altitudes. The predictions were qualitatively verified by subsequent testing of the engine in the PSL. In a previous study, analysis of select PSL test data points helped to calibrate the engine icing computational tool to assess the risk of ice accretion. This current study is a continuation of that data analysis effort. The study focused on tracking the variations in wet bulb temperature and ice particle melt ratio through the engine core flow path. The results from this study have identified trends, while also identifying gaps in understanding as to how the local wet bulb temperature and melt ratio affects the risk of ice accretion and subsequent engine behavior.

Jorgenson, Philip C. E.↗

NASA NTRS2014

Modeling of Commercial Turbofan Engine with Ice Crystal Ingestion; Follow-On

Jorgenson, Philip C. E.↗

DOE OSTI2022

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗