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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods

Air plasma sprayed (APS) flash coatings on high velocity oxygen fuel (HVOF) bond coatings are well known to extend the lifetime of thermal barrier coatings (TBCs). Recent work compared flash coatings of NiCoCrAlY and NiCoCrAlYHfSi applied to both rods and disk substrates of alloy 247. For rod specimens, 100 h cycles were used at 1100 °C in wet air. Both flash coatings significantly improved the lifetime compared to HVOF-only and vacuum plasma spray (VPS)-only MCrAlY bond coatings with no statistical difference between the two flash coatings. For disk specimens tested in 1 h cycles at 1100 °C in wet air, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. The flash coatings formed a mixed oxide-metal zone that appeared to inhibit crack formation and therefore extend lifetime. In addition to the flash coating increasing the bond coating roughness, the underlying HVOF layer acted as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Here, the lower Y+Hf content in the Y-only flash coating appeared to minimize oxidation in the flash layer, thereby increasing the benefit compared to a NiCoCrAlYHfSi flash coating.

42 ENGINEERING↗
DOE OSTI2020

Optical Investigation of Catalyst Heating Operation in a Light-Duty Compression-Ignition Engine

It is well known that cold start engine operation contributes a majority of tail-pipe emissions during a vehicle drive cycle. Aftertreatment catalysts have poor conversion efficiency during this period due to low conversion efficiency at temperatures less than their light-off temperature. A late post injection strategy, with a delayed injection to increase exhaust enthalpy, can help decrease the time required to heat-up the catalyst. However, late injections into conditions with decreasing temperature and density can result in high emissions and combustion instability. In this study a three-injection strategy with a late-post injection was investigated in an optically-accessible engine. For the first two injections (pilot and main) timing and duration were held constant as the post injection timing was swept and duration varied to hold load constant, at a relevant light-load catalyst heating operating condition. Simultaneous double-pass schlieren and OH chemiluminescence data were acquired in an optically-accessible 0.4 L single-cylinder engine to understand spray characteristics and combustion behavior for #2 diesel fuel. Optical images analysis revealed higher liquid penetration and lower vaporization of the liquid fuel jet as post injection is retarded. It is also observed that retarding post injection timing to +25 CAD resulted in lower observed soot concentration in the piston bowl.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

A scalable approach of using biomass derived glycerol to synthesize cathode materials for lithium-ion batteries

Glycerol, a main byproduct of biodiesel, was used as the fuel agent in a scalable flame-assisted spray pyrolysis approach to synthesize micron-size cathode materials. Single droplet combustion, particle morphology, and electrochemical performance were examined considering the effects of salt concentration, water addition, and post-annealing time on synthesizing Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 (NCM111) cathode materials. Single droplet tests showed that a sufficient amount of water in the glycerol-based precursor could delay droplet inflation and ignition. Moreover, using a two-fluid atomization nozzle, spray tests demonstrated that adding water would result in less wrinkled and more uniform particles. Nevertheless, increasing water proportion in the precursor could reduce the reaction heat, resulting in that samples prepared with water addition needed longer post-annealing time to improve their electrochemical performance. Using the precursor without water, the best performed NCM111 cathode material was synthesized with only 2 h of post-annealing. It has a discharge capacity of 163.3 mAh/g at 0.1C and 85.5% capacity retention at 1C after 100 cycles. Furthermore, the current work confirmed the capability of using glycerol as a sustainable fuel agent to synthesize NCM111 cathode materials, and also provided basic conditions for the development of large-scale production in the future.

25 ENERGY STORAGE↗
DOE OSTI2020

Cold spray technology in nuclear energy applications: A review of recent advances

Cold spray technology is a promising solid-state, powder-based deposition methods for fabrication of coatings, near-net-shape manufacturing, and component repair. In recent years, this technology has been investigated for many applications in the nuclear energy sector. For example, it has been explored for the deposition of coatings of corrosion and oxidation materials on zirconium-alloys fuel claddings in light water reactors (LWR) for achieving more accident-tolerant fuel (ATF) cladding. Other examples of its use for nuclear energy applications include coatings for enhancements in wear resistance and heat transfer, near-net shape manufacturing of next-generation fuel claddings of oxide dispersion-strengthened (ODS) steels, and for mitigation and repair of potential chloride induced stress corrosion cracking in used fuel storage canister systems. This work reviews published literature on the application of cold spray process for nuclear energy applications, while pointing to gaps that have yet to be addressed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An energy model of droplet impingement on an inclined wall under isothermal and non-isothermal environments

The observation of spray-wall interaction is of great importance to understand the dynamics that occur during fuel impingement onto the chamber wall or piston surfaces in internal combustion engines. It is found that the maximum spreading length of an impinged droplet can provide a quantitative estimation of heat transfer and energy transformation for spray-wall interaction. Furthermore, it influences the air-fuel mixing and hydrocarbon and particle emissions at combusting conditions. In this paper, an analytical model of different droplet-wall impingement conditions is developed in terms of βm (dimensionless maximum spreading length, the ratio of maximum spreading length to initial droplet diameter) to understand the detailed impinging dynamic process. These conditions are grouped as: a single diesel droplet impinging on the wall with different inclined angles (α); cold wall - heated droplet and heated wall - cold droplet impingement when inclined angle of the wall is 0°, respectively. The analytical model is built up based on the energy conservation that considers kinetic energy, gravitation energy, and surface energy before impingement, as well as viscous dissipation, gravitation energy, adhesion energy, deformation energy, and heat energy after impingement. The experimental work of diesel droplet impinging on an inclined wall is performed at a certain range of the Weber number (We of 33 to 420) with various inclined angles (α of 0° to 45°), while for inclined angle is 0°, droplet and wall temperature are varied from 25°C to 150°C to study the effects of the inclined angle and temperature on the temporal evolution of the post-impingement characteristics (i.e. droplet spreading length, dynamic contact angle). The analytical model is validated and evaluated at the aforementioned experimental operating points. The validated model can be employed to predict maximum spreading length of the droplet impinged on the wall. It is further utilized to determine the transition from capillary regime to kinetic regime, then to viscous regime at different inclined angle of the wall.

42 ENGINEERING↗
DOE OSTI2020

Application of electrospinning for the fabrication of proton-exchange membrane fuel cell electrodes

We report electrospun materials have been gaining great interest in the energy sector. Their tunability and robustness make them highly attractive, particularly for proton-exchange membrane fuel cell (PEMFC) electrodes. Conventional PEMFC electrodes, prepared by either spraying, painting, or slot-die coating, have not yet met the needs of large-scale PEMFC use. Electrospinning of fibrous materials has already shown great promise as an alternative methodology for electrode fabrication. Electrospinning has been used in fuel cell electrodes through two primary means: (1) segmented carbon or inorganic fibers to serve as precious metal catalyst support, and (2) high aspect ratio polymer/particle fibers to serve directly as the electrode. The use of electrospun fibrous electrodes has led to improved PEMFC durability and increased power output at low catalyst loadings, both of which are of paramount importance to large-scale commercialization of PEMFC electric vehicles.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Automation of Solid Oxyde Electrolyzer Cell (SOEC) & Stack Assembly

The work performed under this agreement before the No/Go decision amounted to the following: 1. Preliminary manufacturing requirements defined by business sensitivity, baseline processes & risk assessment; 2. Process & materials development, in-line gauge exploration, and preliminary automation work used to reduce risk & further refine equipment specifications; 3. “Request for Quote” issued to multiple suppliers for major equipment; 4. Application specific equipment, hardware, and fixturing will be more beneficial to fabricate inhouse; 5.Current proposals & estimates meet cycle time, capital spend, & direct labor; space is on target but requires awareness; 6. Team will continue to explore opportunities to reduce risk (dry time, traceability); 7. Go / No-Go, Purchase Orders, Equipment build & commissioning next All other future task were not completed because during the Go /No-Go decision it was confirmed this project was a "No-Go" and did not proceed past BP1; these included the following: 1. Preliminary manufacturing requirements defined by business sensitivity, baseline processes & risk assessment; 2. Process & materials development, in-line gauge exploration, and preliminary automation work used to reduce risk & further refine equipment specifications; 3. “Request for Quote” issued to multiple suppliers for major equipment; 4. Application specific equipment, hardware, and fixturing will be more beneficial to fabricate inhouse; 5. Current proposals & estimates meet cycle time, capital spend, & direct labor; space is on target but requires awareness; 6. Team will continue to explore opportunities to reduce risk (dry time, traceability) In final preparation of the termination of the Automation of Solid Oxyde Electrolyzer Cell (SOEC) & Stack Assembly, Cummins has purchased no equipment with government funds, and there is no government-owned property in Cummins possession related to this project. Minimal labor and travel were completed and paid. This acts as the Final technical report and concludes our business with DOE on this grant.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Optimized piston temperature control in gaseous fuel hydrogen engine system

Operating a gaseous fuel engine system includes combusting a mixture containing a gaseous hydrogen fuel and air in a cylinder of an engine, varying an operating parameter of the engine to which a crown surface temperature of a piston within the cylinder is responsive, and populating a temperature model based on a value of the varied operating parameter. Operating a gaseous fuel engine system further includes operating an oil spray apparatus to spray oil onto the piston based on the populated temperature model, and maintaining the crown surface temperature of the piston between a high temperature limit and a pre-ignition mitigation temperature limit based on the operating of the oil spray apparatus. Related apparatus and control logic is also disclosed.

Bochart, Michael R.↗
DOE OSTI2025

Analysis of soot formation from aviation fuels in laminar counterflow flames

Combustion emissions from aviation contribute to the formation of condensation trail (contrail) that can lead to the formation of anthropogenic cirrus clouds. Ice particles that form contrails are observed to have a linear correlation with soot particle number density. Synthetic aviation fuels (SAFs) offer a promising route to mitigate the production of soot particles while also increasing energy security. Although studies have focused on combustion and spray behavior, the detailed investigation of soot formation processes for different jet fuels and their impact on models for computational fluid dynamics (CFD) applications is not well understood. Moreover, experimental measurements of soot for canonical flames using Synthetic aviation fuels (SAF) for model validation remain scarce. To address this, we use employed the Lawrence Livermore National Laboratory (LLNL) detailed soot model based on the discrete sectional method. Additionally, we develop two reduced chemical mechanisms for Jet-A and Alcohol-to-Jet (C1) that are suitable for turbulent flame simulations and couple them with the Hybrid Method of Moments (HMOM). The detailed and reduced model frameworks are validated against experimental measurements of soot volume fraction (ƒ ν ) from a counterflow burner experiment previously reported in the literature. Given the good agreement between modeling results and experimental measurements for the (1) spatial distribution of ƒ ν and (2) the non-linear variation of peak ƒ ν with strain rate, we further investigate the modeled sub-processes (nucleation, condensation, surface growth, and oxidation) using the LLNL model to analyze the assumptions in the reduced model framework. Furthermore, the results indicate a significant contribution from resonant radicals to the surface growth of soot particles, which are not accounted for in the current implementation of HMOM and could help reconcile soot predictions by the reduced model with observations.

Counterflow↗
DOE OSTI2023

Measurement of needle and armature dynamics in a gasoline direct injector by high-speed neutron imaging

In modern spark ignition engines, precise delivery of fuel with gasoline direct injection has become increasingly important in the effort to meet ever stricter efficiency and emissions regulations. Use of multiple small close-coupled injections has become more common in attempt to precisely control fuel distribution in the cylinder, but these strategies are hindered by nonlinear injection effects due to operation in the ballistic region of the solenoid-operated valve and due to armature bounce at the end of injection. Understanding the internal dynamics of the injector is crucial to minimizing and controlling non-linearity and shot-to-shot variation, but the experimental techniques available to date are capable only of tracking the position of either the top of the needle (via laser sensors or by monitoring current and voltage in the solenoid coil) or the bottom of the needle (via transparent nozzles or high-speed x-ray imaging). Furthermore, a complete picture of the axial and radial motion of valve needle has until now remained elusive. In this work, we present high-speed ensemble neutron transmission imaging of an entire 8-hole gasoline direct injector operating at 200 bar, allowing for both visualization and quantification of the actuation dynamics including lift and wobble of the valve ball, oscillation and bending of the valve needle, lift, rocking, and bounce of the armature, compression of the springs, and radial swelling of the solenoid during energization. Because neutrons offer high penetration through the metal injector while also being sensitive to the 1 H nuclei in fuel molecules, it is also possible to simultaneously see the fluid dynamics of the injection process, including filling of the sac volume, emanation of the spray through the nozzle holes and into the downstream gas, and the formation and evolution of fuel films on the tip of the injector and the walls of the spray container.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

The use of partial fuel stratification to enable stable ultra-lean deflagration-based Spark-Ignition engine operation with controlled end-gas autoignition of gasoline and E85

Lean operation of Spark-Ignition engines can provide higher thermal efficiency compared to standard stoichiometric operation. However, for a homogeneous lean mixture, the associated reduction of flame speeds becomes an important issue from the perspective of robust ignition and fast flame spread throughout the charge. This study is focused on the use of a lean partial fuel stratification strategy that can stabilize the deflagration, while sufficiently fast combustion is ensured via the use of end-gas autoignition. The engine has a spray-guided Direct-Injection Spark-Ignition combustion system and was fueled with either a high-octane certification gasoline or E85. Partial fuel stratification was achieved using several fuel injections during the intake stroke in combination with a small pilot-injection concurrent with the Spark-Ignition. The results reveal that partial fuel stratification enables very stable combustion, offering higher thermal efficiency for parts of the load range in comparison to well-mixed lean and stoichiometric combustion. The heat release and flame imaging demonstrate that the combustion often has three distinct stages. The combustion of the pilot-injected fuel, ignited by the normal spark, acts as a “super igniter,” ensuring a very repeatable initiation of combustion, and flame incandescence reveals locally rich conditions. The second stage is mainly composed of blue flame propagation in a well-mixed lean mixture. The third stage is the compression autoignition of a well-mixed and typically very lean end-gas. The end-gas autoignition is critical for achieving high combustion efficiency, high thermal efficiency, and stable combustion. Partial fuel stratification enables very effective combustion-phasing control, which is critical for controlling the occurrence and intensity of end-gas autoignition. Comparing the gasoline and E85 fuels, it is noted that achieving end-gas autoignition for the higher octane E85 requires a more aggressive compression of the end-gas via the use of a more advanced combustion phasing or higher intake-air temperature.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Spray formation mechanism of diverging-tapered-hole GDI injector and its potentials for GDI engine applications

The gasoline-direct-injection market recently, which has shown the improved spray atomization and lower engine particulate emissions compared to conventional straight-hole nozzles. However, the near-nozzle spray formation mechanism associated with this atomization potential of the diverging-he potentials of the diverging-tapered-hole nozzle for GDI engine applications. The analyses focus on the in- and near-nozzle flow structure, and flow dynamics and stability outside the nozzle. We find that the results showed that the diverging-tapered-hole nozzle coupled with proper hole length generated the radially expanding crescent-moon-like flow structure in the hole that promoted the spray atomization and dispersion outside the nozzle. The expansion of the hole cross-sectional area in the diverging-tapered-hole nozzle was appeared to attenuate the mutual interactions of fuel flows in the hole from various origins that formed rather stable sprays. These flow characteristics are discussed to be promising for the compact and robust spray generation for GDI engine applications.

42 ENGINEERING↗
DOE OSTI2020

Fabrication of high-performance gas-diffusion-electrode based membrane-electrode assemblies

This paper demonstrates the fabrication and processing steps required to produce high performance fuel cell membrane electrode assemblies (MEAs) based on spray-coated gas-diffusion electrodes (GDEs). It is demonstrated that coating the catalyst layer with a thin layer of ionomer and then hot pressing the GDEs to the membrane is required to achieve comparable catalyst activity and air performance to catalyst-coated-membrane MEAs. We show that there is a critical amount of ionomer required to achieve maximized performance. Using electron microscopy, we show that the combination of the ionomer overlayer and hot-pressing bonds the catalyst layer to the membrane, increasing the interfacial contact area and quality of this interface. We also find that the ionomer overlayer smooths the surface of the GDE and provides increased contact area between the GDE and the membrane. Additionally, we demonstrate that much less ionomer is required for high-performance than has been previously reported. Through model fitting of electrochemical impedance spectroscopy, we show that this improvement in the catalyst layer - membrane interface reduces the effective catalyst layer resistance, which reduces Ohmic losses and increases catalyst utilization.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Model development for flash boiling spray and validations with isooctane, hexane, ethanol and their binary mixtures

The objective of this study is to develop a comprehensive model for spray atomization under the consideration of flash boiling, which includes nucleation, bubble growth, and droplet breakup. Although flash boiling has been previously studied, there is still no well-established analytical and numerical model of their mechanisms, or general guidelines on the implementation of this atomization strategy. In this study, detailed formulations are elaborated for the unified spray atomization model under both non-flash and flash boiling conditions. Next, the model was implemented into CFD software and 3-D simulations were performed for model validations. Two fuel blends are tested: ethanol-isooctane blends and hexane-isooctane blends. Simulation results were compared with the experimental measurements conducted using two methodologies, DBI (Diffuse Backlight Imaging) system for spray images captured by a high-speed camera, and a PDA (Phase Doppler Anemometry) system for droplet size measurement during the spray injection process. It was found that the current flash boiling model can accurately capture the spray characteristics under different environment conditions, such as the spray plume interactions and liquid penetration. The averaged Sauter mean diameter (SMD) calculations match the measurement sufficiently well. The spray structures for both single- and multi-component fuels during the injection process are well represented by current model.

42 ENGINEERING↗