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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

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DOE OSTI2025

Self-Lubricating Bushing Testing for John Day Dam Ka plan Turbine Replacement

The goal of this testing program is to find suitable self-lubricated alternatives to replace the in use oil lubricated grooved-bronze bushing in Kaplan runner hubs that are currently being utilized at John Day Dam operated by the U.S. Army Corps of Engineers (USACE). Scaled bushing testing utilizing a Pacific Northwest National Laboratory designed, fabricated, and operated Bushing Test Stand under the direction and funding from USACE determined that self-lubricated bushings tested appear capable of outperforming the current oil-lubricated bronze bushings. Performance tests are focused on durability which includes cyclic load bearing properties and articulations under various loading scenarios. This testing was performed at nominally 1/5 th scale. A scaling sensitivity analysis determined that scaled testing results apply to prototypic size. This report shows the direct comparison between the current baseline bronze bushing to self-lubricated bushings from various manufacturers. Bushing data like coefficient of friction and bushing material loss (associated with bushing wear) was determined. Self-lubricated bushings tested include products manufactured specifically for hydropower applications by the following companies: Trelleborg, Kamatics, Anonymous, and Tenneco/Deva.

42 ENGINEERING↗

NASA NTRS1985

Replaceable blade turbine and stationary specimen corrosion testing facility

A facility was constructed to provide relatively low cost testing of hot section turbine blade and vane materials under hot corrosion conditions more akin to service environments. The facility consists of a small combustor whose pressurized gas flow can be directed to either a test section consisting of three small cascaded specimens or to a partial admittance single-stage axial flow turbine. The turbine rotor contains 28 replaceable turbine blades. The combustion gases resulting from the burning of Jet A-l fuel can be seeded with measured amounts of alkali salts. This facility is described here along with preliminary corrosion test results obtained during the final checkout of the facility.

Santoro, G. J.↗

DOE OSTI2021

Biological Response Models: Predicting Injury and Mortality of Fish During Downstream Passage through Hydropower Facilities

This report describes the U.S. Department of Energy’s HydroPASSAGE project efforts to develop and collect biological response models for integration into the Biological Performance Assessment (BioPA) toolset and the Hydropower Biological Evaluation Toolset (HBET). These models help understand how fish are likely to respond during dam passage when exposed to hydraulic and physical stressors associated with turbines and other hydropower structures. When fish pass through hydropower facilities, they may encounter several stressors, of which the three most common are collision, rapid decompression, and fluid shear. Specialized equipment has been used to develop 99 biological response models for exposure to blade strike, rapid decompression, or fluid shear. The models were gathered from the literature or developed as part of this effort and include models for 31 different species of fish that have various predicted endpoints (i.e., injury or mortality). Among these models, considerable variation in susceptibility to the stressors has been observed from one species to another, and a species’ susceptibility to one stressor does not necessarily indicate similar susceptibility to another. Although several species have been examined, it is still unclear how many other species, which may have different morphological traits, may respond to these stressors, so further examination of the different species is needed. These models can and have been applied in several different cases, often using the BioPA toolset and HBET, to better understand the potential for injury and mortality that may occur during fish passage at hydropower facilities, including specific applications, such as turbine replacement, the installation of new turbines, or changing operations of currently installed turbines. As hydropower is continually developed to meet the electricity needs of society, tools such as HBET and BioPA, used with the integrated biological response models, will aid in the development of technologies and strategies that avoid, minimize, mitigate, or manage environmental effects.

13 HYDRO ENERGY↗

NASA NTRS2007

Conceptual Design and Feasibility of Foil Bearings for Rotorcraft Engines: Hot Core Bearings

Recent developments in gas foil bearing technology have led to numerous advanced high-speed rotating system concepts, many of which have become either commercial products or experimental test articles. Examples include oil-free microturbines, motors, generators and turbochargers. The driving forces for integrating gas foil bearings into these high-speed systems are the benefits promised by removing the oil lubrication system. Elimination of the oil system leads to reduced emissions, increased reliability, and decreased maintenance costs. Another benefit is reduced power plant weight. For rotorcraft applications, this would be a major advantage, as every pound removed from the propulsion system results in a payload benefit.. Implementing foil gas bearings throughout a rotorcraft gas turbine engine is an important long-term goal that requires overcoming numerous technological hurdles. Adequate thrust bearing load capacity and potentially large gearbox applied radial loads are among them. However, by replacing the turbine end, or hot section, rolling element bearing with a gas foil bearing many of the above benefits can be realized. To this end, engine manufacturers are beginning to explore the possibilities of hot section gas foil bearings in propulsion engines. This overview presents a logical follow-on activity by analyzing a conceptual rotorcraft engine to determine the feasibility of a foil bearing supported core. Using a combination of rotordynamic analyses and a load capacity model, it is shown to be reasonable to consider a gas foil bearing core section. In addition, system level foil bearing testing capabilities at NASA Glenn Research Center are presented along with analysis work being conducted under NRA Cooperative Agreements.

Howard, Samuel A.↗

NASA NTRS2008

Preliminary Analysis for an Optimized Oil-Free Rotorcraft Engine Concept

Recent developments in gas foil bearing technology have led to numerous advanced high-speed rotating system concepts, many of which have become either commercial products or experimental test articles. Examples include Oil-Free microturbines, motors, generators and turbochargers. The driving forces for integrating gas foil bearings into these high-speed systems are the benefits promised by removing the oil lubrication system. Elimination of the oil system leads to reduced emissions, increased reliability, and decreased maintenance costs. Another benefit is reduced power plant weight. For rotorcraft applications, this would be a major advantage, as every pound removed from the propulsion system results in a payload benefit. Implementing foil gas bearings throughout a rotorcraft gas turbine engine is an important long-term goal that requires overcoming numerous technological hurdles. Adequate thrust bearing load capacity and potentially large gearbox applied radial loads are among them. However, by replacing the turbine end, or hot section, rolling element bearing with a gas foil bearing many of the above benefits can be realized. To this end, engine manufacturers are beginning to explore the possibilities of hot section gas foil bearings in propulsion engines. This paper presents a logical follow-on activity by analyzing a conceptual rotorcraft engine to determine the feasibility of a foil bearing supported core. Using a combination of rotordynamic analyses and a load capacity model, it is shown to be reasonable to consider a gas foil bearing core section.

Howard, Samuel A.↗

NASA NTRS2008

System Study for Axial Vane Engine Technology

The purpose of this engine feasibility study was to determine the benefits that can be achieved by incorporating positive displacement axial vane compression and expansion stages into high bypass turbofan engines. These positive-displacement stages would replace some or all of the conventional compressor and turbine stages in the turbine engine, but not the fan. The study considered combustion occurring internal to an axial vane component (i.e., Diesel engine replacing the standard turbine engine combustor, burner, and turbine); and external continuous flow combustion with an axial vane compressor and an axial vane turbine replacing conventional compressor and turbine systems.

Badley, Patrick R.↗

DOE OSTI2022

Integration of Pumped Heat Energy Storage with Fossil-Fired Power Plant (Final Report)

The project team of Southwest Research Institute ® (SwRI ® ), Malta Inc. (Malta), and Luminant Generation Company LLC (Luminant) completed a feasibility study for the integration of a 100-MW, 10-hour (1000-MWh) Malta Pumped Heat Energy Storage (MPHES) system with multiple full-sized fossil-fired electricity generation units (EGU) in Luminant portfolio. MPHES is a long-duration, molten-salt-energy storage technology that uses turbomachinery and heat exchangers to transfer energy to a thermal storage media when charging, and removes the heat in a similar fashion when discharging. With high round trip efficiency (60-65%) and long lifespan (30+ years), MPHES provides economic benefits to the fossil-asset owners that can be scaled to integrate with assets across their portfolio. This technology uses hardware components, workforce personnel, and skillsets similar to those used by fossil EGUs, allowing for synergy when co-locating the two technologies. Luminant has approximately 39,000 megawatts of generation across 12 states, operating in six of the seven competitive markets in the U.S. and powered by a diverse portfolio of natural gas, nuclear, coal, and solar facilities. The DeCordova plant in Granbury, Texas, a simple cycle natural gas peaker power plant, was used as the fossil-fired asset in this project. The local market in Granbury, Texas has many influences, including several nearby power plants, a Luminant-owned nuclear plant (Comanche Peak), and substantial wind energy, which causes both negative pricing at night and high market volatility. Reducing false starts of the DeCordova plant and better responding to market volatility would be an economic advantage. Luminant is currently integrating battery storage plant on site to begin addressing these challenges. Integrating long-duration storage, like MPHES, would expand this capability beyond one hour of storage and have the potential to greatly reduce the total number of gas turbine starts. The MPHES charging requirement could help offset the overnight operating costs of Comanche Peak, which cannot load follow, and the nearby Luminant-owned Wise County combined cycle plant that cycles too often. Following the assessment of Luminant’s ERCOT-based portfolio for integration compatibility with Malta’s PHES system and the project tasks of conceptual study, technoeconomic analysis, technology gap assessment, and commercialization plan, the project team effort has resulted in several key outcomes: (1) Identification of market trends in a high-wind penetration market outside a major metropolitan area; (2) Creation of a dispatching model for the MPHES system and the pairing of Li-ion battery with a gas turbine in a real time market; (3) Revenue and cost estimations for operating MPHES alongside a gas peaker plant with real dispatching considerations and comparison with variations in the Malta implementation, including doubling the storage capacity and using two discharge drivetrains; (4) Potential carbon emission reductions possible by replacing gas turbine operation with Malta PHES operation; and (5) Summary of literature-based future market predictions for Texas.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

A scientific framework for sustainable hydropower with improved fish passage

Not Available

13 HYDRO ENERGY↗

NASA NTRS1982

Surface protection overview

A first-cut integrated environmental attack life prediction methodology for hot section components is addressed. The HOST program is concerned with oxidation and hot corrosion attack of metallic coatings as well as their degradation by interdiffusion with the substrate. The effects of the environment and coatings on creep/fatigue behavior are being addressed through a joint effort with the Fatigue sub-project. An initial effort will attempt to scope the problem of thermal barrier coating life prediction. Verification of models will be carried out through benchmark rig tests including a 4 atm. replaceable blade turbine and a 50 atm. pressurized burner rig.

Levine, S. R.↗

NASA NTRS2001

A Cooling System for the EAPU Shuttle Upgrade

The Shuttle orbiter currently uses hydrazine-powered APU's for powering its hydraulic system pumps. To enhance vehicle safety and reliability, NASA is pursuing an APU upgrade where the hydrazine powered turbine is replaced by an electric motor pump and battery power supply. This EAPU (Electric APU) upgrade presents several thermal control challenges most notably the new requirement for moderate temperature control of high-power electron ics at 132 of (55.6 C). This paper describes how the existing Water Spray Boiler (WSB), which currently cools the hydraulic fluid and APU lubrication oil, is being modified to provide EAPU thermal management.

Tongue, Stephen↗

DOE OSTI2026

Update on Model Specification Development of Ternary Pumped Storage Technologies [Slides]

T-PSH is an innovative structure of C-PSH that features two turbines, one for pumping and one for generation, replacing the single turbine in C-PSH. These turbines are housed in separate chambers, with an additional set of penstocks connecting the pump turbine to the hydraulic system. This structure enables T-PSH to operate in an HSC mode, allowing for simultaneous pumping and generation, which provides greater operational flexibility compared to C-PSH. To model T-PSH's HSC mode, a user defined turbine and governor system model is required, including the shared penstock model and additional pump turbine model. This specification will focus on the details of the user-defined turbine and governor model, which leverages the HYGOV model.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems

Gearbox and wind turbine design and application standards have contributed significantly to improvements in reliability over the past two decades. The International Electrotechnical Commission (IEC) 61400-4 standard of wind turbine gearbox design is currently being revised by a joint working group (JWG) of experts in IEC TC 88 (wind energy) and International Organization for Standardization (ISO) TC60 (gears) to further that effort. Experts from ISO TC4 (rolling bearings) and ISO TC28 (lubricants) have actively participated. This revision has implemented lessons learned from industry use of edition 1 since its publication in 2012. The main document, IEC 61400-4, was pared down to essential design requirements and application-specific recommendations along with a design verification framework. The JWG leveraged concurrent development of other standards, such as IEC 61400-8 on wind turbine structures, to replace edition 1 content. These are described along with how this works with the IEC Renewable Energy certification scheme for wind turbines (IECRE-WE). The JWG recognized the interest in maintaining informative parts of edition 1 including annexes on wind turbine architecture and loads, bearing and gear arrangements, bearing selection, lubrication system descriptions and lubricant performance recommendations. This information was retained in two technical reports: IEC/TR 61400-4-2 Lubrication and IEC/TR 61400-4-3 Explanatory Notes. Additionally, a technical specification, IEC/TS 61400-4-1, was drafted to provide a reliability calculation method for comparing different design options or conditions. Salient elements of these documents are described. All four documents were recently distributed for IEC/ISO review, ballot, and comment. Publication is expected in 2023.

gearbox↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems: Preprint

ENGINEERING,WIND ENERGY↗

NASA NTRS2013

Design Considerations for Ceramic Matrix Composite Vanes for High Pressure Turbine Applications

Issues associated with replacing conventional metallic vanes with Ceramic Matrix Composite (CMC) vanes in the first stage of the High Pressure Turbine (HPT) are explored. CMC materials have higher temperature capability than conventional HPT vanes, and less vane cooling is required. The benefits of less vane coolant are less NOx production and improved vane efficiency. Comparisons between CMC and metal vanes are made at current rotor inlet temperatures and at an vane inlet pressure of 50 atm.. CMC materials have directionally dependent strength characteristics, and vane designs must accommodate these characteristics. The benefits of reduced NOx and improved cycle efficiency obtainable from using CMC vanes. are quantified Results are given for vane shapes made of a two dimensional CMC weave. Stress components due to thermal and pressure loads are shown for all configurations. The effects on stresses of: (1) a rib connecting vane pressure and suction surfaces; (2) variation in wall thickness; and (3) trailing edge region cooling options are discussed. The approach used to obtain vane temperature distributions is discussed. Film cooling and trailing edge ejection were required to avoid excessive vane material temperature gradients. Stresses due to temperature gradients are sometimes compressive in regions where pressure loads result in high tensile stresses.

Boyle, Robert J.↗

DOE OSTI2023

Phase stability and tensorial thermal expansion properties of single to high-entropy rare-earth disilicates

Temperature limitations in nickel-base superalloys have resulted in the emergence of SiC-based ceramic matrix composites as a viable replacement for gas turbine components in aviation applications. Higher operating temperatures allow for reduced fuel consumption but present a materials design challenge related to environmental degradation. Rare-earth disilicates (RE 2 Si 2 O 7 ) have been identified as coatings that can function as environmental barriers and minimize hot component degradation. In this work, single- and multiple-component rare-earth disilicate powders were synthesized via a sol-gel method with compositions selected to exist in the monoclinic C 2/m phase (β phase). Phase stability in multiple cation compositions was shown to follow a rule of mixtures and the C 2/m phase could be realized for compositions that contained up to 25% dysprosium, which typically only exists in a triclinic, P $\bar1$, phase. All compositions exhibited phase stability from room temperature to 1200°C as assessed by X-ray diffraction. The thermal expansion tensors for each composition were determined from high-temperature synchrotron X-ray diffraction and accompanying Rietveld refinements. It was observed that ytterbium-containing compositions had larger changes in the α 31 shear component with increasing temperature that led to a rotation of the principal axes. Principal axes rotation of up to 47° were observed for ytterbium disilicate. The results suggest that microstructure design and crystallographic texture may be essential future avenues of investigation to ensure thermo-mechanical robustness of rare-earth disilicate environmental barrier coatings.

36 MATERIALS SCIENCE↗

NASA NTRS1983

Hybrid hydrostatic/ball bearings in high-speed turbomachinery

A high speed, high pressure liquid hydrogen turbopump was designed, fabricated, and tested under a previous contract. This design was then modified to incorporate hybrid hydrostatic/ball bearings on both the pump end and turbine end to replace the original conventional ball bearing packages. The design, analysis, turbopump modification, assembly, and testing of the turbopump with hybrid bearings is presented here. Initial design considerations and rotordynamic performance analysis was made to define expected turbopump operating characteristics and are reported. The results of testing the turbopump to speeds of 9215 rad/s (88,000 rpm) using a wide range of hydrostatic bearing supply pressures are presented. The hydrostatic bearing test data and the rotordynamic behavior of the turbopump was closely analyzed and are included in the report. The testing of hybrid hydrostatic/ball bearings on a turbopump to the high speed requirements has indicated the configuration concept is feasible. The program has presented a great deal of information on the technology requirements of integrating the hybrid bearing into high speed turbopump designs for improved bearing life.

Nielson, C. E.↗

NASA NTRS1993

Vortex-Shedding Meters For Liquid And Liquid/Gas Flows

Flowmeters without moving parts developed as replacements for conventional turbine flowmeters. No maintenance required so meters installed permanently. In vortex-shedding flowmeter, piezoelectric or other suitable transducer probe senses changes of pressure caused by passage of vortices. Electronic circuitry processes pressure-change signals to extract vortex-passage frequency representing rate of flow.

Howard, Robert H.↗

NASA NTRS1991

Low Flow Vortex Shedding Flow Meter for Hypergolics/all Media

A family of vortex shedding flow meters, for measurement of hypergol flows, was designed and fabricated. The test loops to evaluate the flow meters for water flow, as well as Freon -113 flow which simulates the hypergolic fluids, were modified and constructed to utilize a pump system which has an output capacity of 200 gpm. Test runs were conducted on the small 1/2 inch model with Freon 113 and on the larger models with water. Results showed that the linearity between the frequency of the vortices and the flow rate of the fluids was very close to that of the turbine flow meter. It is suggested that the vortex shedding flow meter is a possible replacement for the existing turbine type.

Thinh, Ngo Dinh↗