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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

X-Ray Phase Contrast Imaging of Liquid Film and Spray Development Inside an Aircraft Engine Swirler

Modern aircraft engines combine liquid fuel and air using an intricate flow device with many fuel and air flow passages. To date, the process by which the fuel atomizes within this swirler set has not been examined directly due to optical access limitations. In this work, high-speed X-ray phase-contrast imaging of a liquid spray inside a gas turbine engine swirler geometry is presented. Measurements were carried out at the 7-BM beamline of the Advanced Photon Source at Argonne National Laboratory using the high-energy broadband X-ray beam. The synchrotron X-ray source provides the necessary photon energy and flux to capture time-resolved fluid phenomena within the confines of the relevant geometry while liquid and air are flowing. Spray nozzle hardware and geometries were provided by the National Jet Fuels Combustion Program (NJFCP), allowing for characterization of the spray using a commercially relevant configuration. Modified swirlers were three-dimensional printed with acrylic to improve imaging access while maintaining influential internal features. Water was used as a surrogate fluid for these studies to demonstrate the visualization capabilities. The experiments were conducted at atmospheric exit pressure conditions with a pressure drop of 6% across the swirler. High-speed imaging of the pilot spray cone revealed sheet breakup several millimeters downstream of the orifice exit, upon interaction with the radial assist air flow. These droplets and ligaments were observed to impinge on the inner filming surface of the swirler and flow toward the exit while developing a tangential flow. Under these conditions, the liquid film grows up to several hundred microns in thickness on the filming surface, and subsequently forms ligaments up to several millimeters in length before breaking up. This work demonstrates the capability of X-ray diagnostics in visualizing liquid flows within solid geometries of technical relevance. Furthermore, the spatial quantification of filming flows and liquid interaction with the swirler air provides validation data for modeling of the multiphase flows and surface interactions within the swirler.

Sforzo, Brandon A.↗
DOE OSTI2017

Integrated Computational Materials Engineering (ICME) Tools for Optimizing Strength of Forged Al-Li Turbine Blades for Aircraft Engines Final Report CRADA No. TC02238.0

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and LIFT Consortium to develop, implement and validate a defect physics-based model to predict mechanical properties of forged Al-Li alloys. LLNL task was to conduct dislocation dynamics simulations of the interaction of dislocations with the primary precipitates providing strength of proposed Al-Li alloys.

42 ENGINEERING↗
DOE OSTI2014

Sonic IR crack detection of aircraft turbine engine blades with multi-frequency ultrasound excitations

Effectively and accurately detecting cracks or defects in critical engine components, such as turbine engine blades, is very important for aircraft safety. Sonic Infrared (IR) Imaging is such a technology with great potential for these applications. This technology combines ultrasound excitation and IR imaging to identify cracks and flaws in targets. In general, failure of engine components, such as blades, begins with tiny cracks. Since the attenuation of the ultrasound wave propagation in turbine engine blades is small, the efficiency of crack detection in turbine engine blades can be quite high. The authors at Wayne State University have been developing the technology as a reliable tool for the future field use in aircraft engines and engine parts. One part of the development is to use finite element modeling to assist our understanding of effects of different parameters on crack heating while experimentally hard to achieve. The development has been focused with single frequency ultrasound excitation and some results have been presented in a previous conference. We are currently working on multi-frequency excitation models. The study will provide results and insights of the efficiency of different frequency excitation sources to foster the development of the technology for crack detection in aircraft engine components.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

High Specific Stiffness Shafts and Advanced Bearing Coatings for Gas Turbine Engines Final Report CRADA No. TC-1089-95

At the time of the CRADA, the largest in-service gas-turbine aircraft engines strove for increased thrust and power density to meet the requirements for take-off thrust, given the increase in take-off gross weight (TOGW) associated with longer range transport requirements. The trend in modem turbo shaft engines was toward turbine shafts with higher and higher length-to-diameter ratios, which reduced the shaft critical speed. Using co nventional shaft materials, this lead to shafts that needed to operate near or above sensitive shaft bending critical speeds, therefore requiring multiple bearings and/ or multiple squeeze-film dampers to control the dynamic response. Using new materials and d esign concepts this project demonstrated the use of new shaft materials which could provide increased shaft speed range above existing maximum engine speeds without encountering a critic al speed event and high vector deflections. This increased main shaft speed also resulted in decreased bearing life associated with lower heat dissipation and higher centrifugal forces. Thus, a limited effort was devoted to feasibility of higher performance bearing coatings to mitigate the speed effects.

42 ENGINEERING↗
DOE OSTI2022

Characterizing Flow Instabilities During Transient Events in the Turbine Rim Seal Cavity

Abstract Gas turbine engine design requires considerations not only for long-term steady operation but also for critical transient events. Aircraft engines undergo significant stress during takeoff and landing, while power generation turbines must be flexible for hot restarts as renewable energy sources come online and offline. During these transient cycles, engines sustain wear and degradation that can lead to a reduction in the lifespan of their components and more frequent, costly maintenance. Cooling flows are often used to mitigate these effects, but can lead to complex and problematic flow interactions. This study uses high-frequency response pressure probes and heat flux gauges in the rim seal cavity of a one-stage research turbine to characterize the properties of large-scale flow structures during transient operation. A continuous-duration turbine testing facility provides the ability to assess the importance of these transients by first reaching steady-state operation before imposing transient behaviors. Although previous studies have conducted similar measurements for steady purge flows and wheel speeds, varying these parameters to simulate transient effects revealed several unique phenomena not identifiable with discrete steady measurements. The measurement approach connects the varied transient parameter to the behavior of the flow structures to enable a better understanding of the type of instability observed and the root cause of its formation. In particular, a relationship between instability cell formation and rim sealing effectiveness was identified using experimental data and was supported through computational simulations.

Engineering↗
DOE OSTI2025

Development of Hydrogen Burner for FT4000® Aeroderivative Engine - Final Report

This report details an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas and ending with improved nozzle concepts for fully robust operation with 100% hydrogen. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) emissions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The design of new fuel/air mixer concepts to improve durability and operability with high hydrogen levels was also completed. A total of eleven new concepts were developed and analyzed, ranging from modifications to the bill-of-materials nozzle to fully clean sheet designs. The concepts were evaluated with non-reacting and reacting flow evaluations to assess the performance of the new hardware designs. Non-reacting tests included Phase Doppler Particle Analysis (PDPA) for droplet size and velocity, mechanical patternation for liquid water flux, and planar laser induced fluorescence (PLIF) with acetone-seeding for gaseous fuel/air mixing characterization. Five scaled candidate fuel nozzle designs, in addition to a scaled bill-of-materials nozzle, were then successfully evaluated in an atmospheric pressure burner rig. The nozzles were evaluated for performance with natural gas, hydrogen/natural gas blends, and pure hydrogen. For 100% hydrogen, the nozzles were evaluated with and without water injection. Optical and infrared imaging of the flame and fuel nozzle was captured. NOx emissions were sampled from fixed emissions probes. The results show measurable differences between the various designs, and the data was used to down-select the two most promising designs to advance to future full pressure rig testing. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water. Two promising nozzle designs have been developed to enable fully robust operation with up to 100% hydrogen. These nozzles require validation at full baseload operating conditions before they can be introduced to the field.

03 NATURAL GAS↗
DOE OSTI2024

OPERATION OF FT4000® SINGLE NOZZLE COMBUSTOR WITH HIGH HYDROGEN

This paper reports initial results from an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) missions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water.

power generation↗
DOE OSTI2020

Data-driven analysis of relight variability of jet fuels induced by turbulence

For safety purposes, reliable reignition of aircraft engines in the event of flame blow-out is a critical requirement. Typically, an external ignition source in the form of a spark is used to achieve a stable flame in the combustor. However, such forced turbulent ignition may not always successfully relight the combustor, mainly because the state of the combustor cannot be precisely determined. Uncertainty in the turbulent flow inside the combustor, inflow conditions, and spark discharge characteristics can lead to variability in sparking outcomes even for nominally identical operating conditions. Prior studies have shown that of all the uncertain parameters, turbulence is often dominant and can drastically alter ignition behavior. For instance, even when different fuels have similar ignition delay times, their ignition behavior in practical systems can be completely different. In practical operating conditions, it is challenging to understand why ignition fails and how much variation in outcomes can be expected. The focus of this work is to understand relight variability induced by turbulence for two different aircraft fuels, namely Jet-A and a variant named C1. A detailed, previously developed simulation approach is used to generate a large number of successful and failed ignition events. Using this data, the cause of misfire is evaluated based on a discriminant analysis that delineates the difference between turbulent initial conditions that lead to ignition or failure. From the discriminant analysis, a compressed sensing algorithm is then applied to help pinpoint the locations of relevant turbulent features. Findings from the discriminant analysis are confirmed with the time history of near kernel properties. Next, a clustering strategy is used to identify ignition and misfire modes. With this approach, it was determined that the cause of ignition failure is different for the two fuels. While it was found that Jet-A is influenced by fuel entrainment, C1 was found to be more sensitive to small scale turbulence features. Finally, a larger variability is found in the ignition modes of C1, which can be subject to extreme events induced by kernel breakdown.

42 ENGINEERING↗
DOE OSTI2020

Solving Recent Challenges for Wrought Ni-Base Superalloys

This paper reviews the status of technology in design and manufacture of new wrought 21 polycrystalline Ni-base superalloys for critical engineering applications. There is a strong 22 motivation to develop new alloys that are capable of operating at higher temperatures to 23 realise improvements in thermal efficiency, which are necessary to achieve environmental 24 targets for reduced emissions of harmful green-house gases. From the aerospace sector, 25 the development of new powder metallurgy and ingot metallurgy alloys are discussed for 26 disk rotor and static applications. New compositions for powder metallurgy contain about 27 50-55% of gamma prime (γ') strengthening precipitates to ensure components operate 28 successfully at temperatures up to 788°C (1450°F). In contrast, new compositions for ingot 29 metallurgy aim to occupy a design space in temperature capability between Alloy 718 and 30 current powder alloys that are in-service, and show levels of γ' of about 30-44%. The focus 31 in developing these alloys was design for manufacturability. To complement the aerospace 32 developments, a review of work to understand the suitability of candidate alloys for multiple 33 applications in Advanced-Ultra Supercritical (AUSC) power plants has been undertaken by 34 Detrois, Jablonski and Hawk from the National Energy Technology Laboratory. In these 35 power plants, steam temperatures are required to reach 700-760°C. The common thread is 36 to develop alloys that demonstrate a combination of high temperature properties, which are 37 reliant on both the alloy composition and microstructure and can be produced readily at the 38 right price. For the AUSC applications, the emphasis is on high temperature strength, long 39 term creep life, phase stability, oxidation resistance and robust welding for fabrications. 40 Whereas for powder disk rotors in aircraft engines, the priority is enhanced resistance to 41 time dependent crack growth, phase stability and resistance to environmental damage, while 42 extending the current strength levels, which are shown by existing alloys, to higher 43 temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Realizing "Net-Zero-Carbon" Sustainable Aviation Fuel

The aviation industry needs renewable and fungible jet fuel - commonly referred to as sustainable aviation fuel (SAF) - to minimize emissions and increase efficiencies. SAF can displace the same, if not more, CO2 equivalent emissions (CO2eq), reduce contrail formation, and increase engine-aircraft efficiencies. Flight represents ~10% of transportation greenhouse gas emissions, with the global consumption of ~400 billion liters of fossil jet fuel in 2019 releasing over 900 million tons of CO2eq. Even with impacts from the COVID-19 global pandemic, the aviation sector is projected to grow with passenger miles expected to double by 2050, relative to 2010. As such, there is an urgent need to produce drop-in aviation fuel from renewables with a dramatically lower carbon footprint.

biojet↗
DOE OSTI2013

A study of the mechanism of laser welding defects in low thermal expansion superalloy GH909

In this paper, we describe experimental laser welding of low-thermal-expansion superalloy GH909. The main welding defects of GH909 by laser in the weld are liquation cracks and porosities, including hydrogen and carbon monoxide porosity. The forming mechanism of laser welding defects was investigated. This investigation was conducted using an optical microscope, scanning electron microscope, energy diffraction spectrum, X-ray diffractometer and other methodologies. The results demonstrated that porosities appearing in the central weld were related to incomplete removal of oxide film on the surface of the welding samples. The porosities produced by these bubbles were formed as a result of residual hydrogen or oxygenium in the weld. These elements failed to escape from the weld since laser welding has both a rapid welding speed and cooling rate. The emerging crack in the heat affected zone is a liquation crack and extends along the grain boundary as a result of composition segregation. Laves–Ni{sub 2}Ti phase with low melting point is a harmful phase, and the stress causes grain boundaries to liquefy, migrate and even crack. Removing the oxides on the surface of the samples before welding and carefully controlling technological parameters can reduce welding defects and improve formation of the GH909 alloy weld. - Highlights: ► It is a new process for the forming of GH909 alloy via laser welding. ► The forming mechanism of laser welding defects in GH909 has been studied. ► It may be a means to improve the efficiency of aircraft engine production.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Characterization of precipitation in gradient Inconel 718 superalloy

Inconel 718 (IN718) superalloy is a well-established material for the application of aircraft engine and power generator due to its excellent performance at high temperatures. The outstanding mechanical properties of IN718 are largely determined by the precipitates. Here, we investigated the precipitation behaviors and the corresponding mechanical properties of the heat-treated gradient IN718 alloy. The microscopy studies reveal that high-density hexagonal η phase with chemistry of Ni 3 (Al,Ti,Nb) formed in the nanograined IN718 alloy after annealing at 700 °C. Additionally, the compressive stress introduced during severe plastic deformation may have prohibited the formation of γ” phase while accelerated the precipitation of γ’ phase, consequently favoring the precipitation of η phase. The corresponding evolution of mechanical behavior of gradient IN718 alloy is investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Understanding the role of flow dynamics in thermoacoustic combustion instability

Thermoacoustic combustion instability is one of the most challenging operational issues in several high-performance, low-emissions combustion technologies, including gas turbines, aircraft engines, rockets, and industrial boilers. Driven by the coupling between combustor acoustics and flame heat release rate fluctuations, thermoacoustic combustion instability can lead to reduced operability, increased emissions, and, in the most extreme cases, catastrophic failure of combustor components. The feedback loop between acoustics and combustion is often facilitated by fluid mechanic oscillations, referred to as “velocity coupling,” whereby acoustic oscillations drive flow fluctuations, which in turn create fluctuations in the flame. The character of these fluid mechanic oscillations is highly dependent on the structure of the flow field and the receptivity of the flow to external excitation. Combustor flow fields use features like fluid recirculation and shear to enhance flame holding and reduce emissions, but these are also the same features that can make the flow receptive to acoustic excitation or even drive self-excited oscillations. Here, in this paper, we discuss the basics of thermoacoustic instability with a focus on the role of hydrodynamic oscillations in typical combustor flows. To facilitate this discussion, we explore the hydrodynamic instability characteristics of several key combustor unit flows (wakes, swirling jets, etc.) and show how the hydrodynamic stability of a flow is an important consideration in determining a combustor’s propensity for thermoacoustic oscillations. Several examples of coupling between hydrodynamics and thermoacoustics are discussed to illustrate this important link. The paper concludes by discussing the potential for designing flow fields that are thermoacoustic instability resistant, either through a reduction in the receptivity of the flow or through nonlinear coupling mechanisms by which self-excited flow instabilities can suppress velocity-coupled combustion oscillations.

42 ENGINEERING↗
DOE OSTI2015

Eddy current sensor for in-situ monitoring of swelling of Li-ion prismatic cells

In-situ monitoring an on-board rechargeable battery in hybrid cars can be used to ensure a long operating life of the battery and safe operation of the vehicle. Intercalations of ions in the electrode material during charge and discharge of a Lithium Ion battery cause periodic stress and strain of the electrode materials that can ultimately lead to fatigue resulting in capacity loss and potential battery failure. Currently this process is not monitored directly on the cells. This work is focused on development technologies that would quantify battery swelling and provide in-situ monitoring for onboard vehicle applications. Several rounds of tests have been performed to spatially characterize cell expansion of a 5 Ah cell with a nickel/manganese/cobalt-oxide cathode (Sanyo, Japan) used by Ford in their Fusion HEV battery pack. A collaborative team of researchers from GE and the University of Michigan has characterized the free expansion of these cells to be in the range of 100×125 microns (1% of total cell thickness) at the center point of the cell. GE proposed to use a thin eddy current (EC) coil to monitor these expansions on the cells while inside the package. The photolithography manufacturing process previously developed for EC arrays for detecting cracks in aircraft engine components was used to build test coils for gap monitoring. These sensors are thin enough to be placed safely between neighboring cells and capable of monitoring small variations in the gap between the cells. Preliminary investigations showed that these coils can be less than 100 micron thick and have sufficient sensitivity in a range from 0 to 2 mm. Laboratory tests revealed good correlation between EC and optical gap measurements in the desired range. Further technology development could lead to establishing a sensor network for a low cost solution for the in-situ monitoring of cell swelling during battery operation.

42 ENGINEERING↗
DOE OSTI2024

Nucleation and Contrail Formation

Condensation trails, or contrails, are aircraft-induced cirrus clouds. They come from the formation of water droplets, later converting to ice crystals as a result of water vapor condensing on aerosols either emitted by the aircraft engines or already present in the upper atmosphere. While there is ongoing debate about their true impact, contrails are estimated to be a major contributor to climate forcing from aviation. We remind that air transportation currently accounts for about 5 % of the global anthropogenic climate forcing, and that it is anticipated that air traffic will double in the coming decade or two. The expected growth reinforces the urgency of the need to develop a plan to better understand contrail formation and persistence, and deploy means to reduce or avoid contrail formation, or greatly mitigate their impact. It is evident that contrails should be part of the picture when developing a plan to make the aviation sector sustainable.

54 ENVIRONMENTAL SCIENCES↗