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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
NASA NTRS2002

Friction pull plug welding: chamfered heat sink pull plug design

Friction Pull Plug Welding (FPPW) is a solid state repair process for defects up to one inch in length, only requiring single sided tooling (OSL) for usage on flight hardware. Experimental data has shown that the mass of plug heat sink remaining above the top of the plate surface after a weld is completed (the plug heat sink) affects the bonding at the plug top. A minimized heat sink ensures complete bonding of the plug to the plate at the plug top. However, with a minimal heat sink three major problems can arise, the entire plug could be pulled through the plate hole, the central portion of the plug could be separated along grain boundaries, or the plug top hat can be separated from the body. The Chamfered Heat Sink Pull Plug Design allows for complete bonding along the ISL interface through an outside diameter minimal mass heat sink, while maintaining enough central mass in the plug to prevent plug pull through, central separation, and plug top hat separation.

Coletta, Edmond R.↗
NASA NTRS2005

Friction pull plug welding: chamfered heat sink pull plug design

The average strength of a pull plug weld is increased and weak bonding eliminated by providing a dual included angle at the top one third of the pull plug. Plugs using the included angle of the present invention had consistent high strength, no weak bonds and were substantially defect free. The dual angle of the pull plug body increases the heat and pressure of the weld in the region of the top one third of the plug. This allows the plug to form a tight high quality solid state bond. The dual angle was found to be successful in elimination of defects on both small and large plugs.

Coletta, Edmond R.↗
NASA NTRS2001

Friction pull plug welding: top hat plug design

Friction Pull Plug Welding is a solid state repair process for defects up to one inch in length, only requiring single sided tooling, or outside skin line (OSL), for preferred usage on flight hardware. The most prevalent defect associated with Friction Pull Plug Welding (FPPW) was a top side or inside skin line (ISL) lack of bonding. Bonding was not achieved at this location due to the reduction in both frictional heat and welding pressure between the plug and plate at the end of the weld. Thus, in order to eliminate the weld defects and increase the plug strength at the plug `top` a small `hat` section is added to the pull plug for added frictional heating and pressure.

Coletta, Edmond R.↗
NASA NTRS2002

Friction pull plug welding: top hat plug design

Friction Pull Plug Welding is a solid state repair process for defects up to one inch in length, only requiring single sided tooling, or outside skin line (OSL), for preferred usage on flight hardware. The most prevalent defect associated with Friction Pull Plug Welding (FPPW) was a top side or inside skin line (ISL) lack of bonding. Bonding was not achieved at this location due to the reduction in both frictional heat and welding pressure between the plug and plate at the end of the weld. Thus, in order to eliminate the weld defects and increase the plug strength at the plug `top` a small `hat` section is added to the pull plug for added frictional heating and pressure.

Coletta, Edmond R.↗
NASA NTRS2016

Friction Pull Plug and Material Configuration for Anti-Chatter Friction Pull Plug Weld

A friction pull plug is provided for use in forming a plug weld in a hole in a material. The friction pull plug includes a shank and a series of three frustoconical sections. The relative sizes of the sections assure that a central one of the sections defines the initial contact point between the hole's sides. The angle defined by the central one of the sections reduces or eliminates chatter as the plug is pulled into the hole.

Littell, Justin Anderson↗
DOE OSTI2025

ZIPPER: Zonal isolation with plug and perf in enhanced reservoirs (Final Technical Report)

Modern multistage hydraulic stimulation treatments in cased wellbores require an effective method of isolating stages between treatments. A commonly used method in the oil and gas industry, plug and perf, is not currently viable for Enhanced Geothermal Systems (EGS) due to limitations of a critical component of the system – the ball drop (flow through) frac plug. Commercially available ball drop frac plugs do not meet the temperature or wellbore diameter requirements needed for use in EGS stimulations. For example, one particular drillable bridge and frac plug line from a large tool developer is only rated to 175 °C, while another is only available up to casing sizes of 5 ½” and rated up to 204 °C. We developed, prototyped, and field tested an upgraded ball drop frac plug to meet the requirements of EGS stimulations, including high-temperature (225+ °C), differential pressure (6000+ psi), and wellbore diameters ranging from 6 5/8” to 10 5/8”. We focused on designs and materials to optimize drillability, a key cost driver in plug and perf systems. The primary objective was to upgrade a drillable frac plug (currently rated to a temperature of 175°C and a pressure of 10,000 psi in 7” casing) to withstand temperatures of 225+°C. The upgraded frac plug was tested in the laboratory as well as in a field trial at a geothermal field. Engineering design and fabrication of the new plug was completed in 2019. Lab testing, validation, and qualification of the plug was completed in 2020. Ultimately the plug was successfully run during a multistage stimulation treatment in a fully horizontal EGS well in 2022. Prior to this project, a ball-drop, flow-through stimulation plug had never been used in a geothermal well. At the conclusion of this project, three different types of zonal isolation plugs were evaluated under full-scale operating conditions across 16 stimulation treatment stages in a first-of-a-kind EGS project called Project Red. This trial included the newly designed high-temperature, large-diameter plug. The plugs met all of 5 the technical requirements for commercial viability. Project Red has since been fully commissioned and is generating electricity on the Nevada grid - the first EGS project to successfully deliver power to the grid in the US.

15 GEOTHERMAL ENERGY↗
NASA NTRS1987

Aeroacoustics of supersonic jet flows from contoured and solid/porous conical plug-nozzles

The results of an experimental study of the acoustic far-field, the shock associated noise, and the nature of the repetitive shock structure of supersonic jet flows issuing from plug-nozzles having externally-expanded plugs with pointed termination operated at a range of supercritical pressure ratios Xi approaching 2 to 4.5 are reported. The plug of one of these plug-nozzles was contoured. The other plug-nozzles had short conical plugs with either a solid surface or a combination of solid/porous surface of different porosities. The contoured and the uncontoured plug-nozzles had the same throat area and the same annulus-radius ratio K = R sub p/R sub N = 0.43. As the result of modifications of the shock structure, the acoustic performance of improperly expanded jet flows of an externally-expanded short uncontoured plug of an appropriate geometry with suitably perforated plug and a pointed termination, is shown to approach the acoustic performance of a shock-free supersonic jet issuing from an equivalent externally-expanded contoured plug-nozzle.

Dosanjh, Darshan S.↗
NASA NTRSDate not supplied

Flow and Noise from Supersonic Plug Nozzles

Nozzles with external plugs are candidates for propulsion of future supersonic aircraft. A model-scale experimental study is conducted exploring the flow and noise characteristics of various plug nozzles. For a given outer nozzle, the plug geometry is varied from conic with various half-angles (lengths) to plugs designed by the method of characteristics (MoC) as well as truncated and porous plugs. So far, noise characteristics and schlieren flow visualization data have been acquired. Limited numerical simulations have also been done addressing thrust performance. The simulations show that the MoC plugs out-perform the conic cases, especially around high Mach number cruise conditions. The experimental data, however, show that the MoC plugs are noisy relative to the conic cases at low Mach number landing and takeoff (LTO) conditions. The increased noise (with MoC at LTO) is accompanied by unsteady turbulent structures and increased jet spreading, as seen in schlieren pictures. At LTO, the longest conic plug is found to be the least noisy. Furthermore, a porous surface on the long conic plug effectively suppresses broadband shock associated noise (BBSN) at higher Mach numbers. Thus, a dilemma remains. MoC design gives best thrust performance at cruise but it is noisy at LTO. A long conic plug, on the other hand, is quieter at LTO but may have unacceptable thrust at cruise.

jets↗
NASA NTRSDate not supplied

Flow and noise from supersonic plug nozzles

Nozzles with external plugs are candidates for propulsion of future supersonic aircraft. A model-scale experimental study is conducted exploring the flow and noise characteristics of various plug nozzles. For a given outer nozzle, the plug geometry is varied from conic with various half-angles (lengths) to plugs designed by the method of characteristics (MoC) as well as truncated and porous plugs. So far, noise characteristics and schlieren flow visualization data have been acquired. Limited numerical simulations have also been done addressing thrust performance. The simulations show that the MoC plugs out-perform the conic cases, especially around high Mach number cruise conditions. The experimental data, however, show that the MoC plugs are noisy relative to the conic cases at low Mach number landing and takeoff (LTO) conditions. The increased noise (with MoC at LTO) is accompanied by unsteady turbulent structures and increased jet spreading, as seen in schlieren pictures. At LTO, the longest conic plug is found to be the least noisy. Furthermore, a porous surface on the long conic plug effectively suppresses broadband shock associated noise (BBSN) at higher Mach numbers. Thus, a dilemma remains. MoC design gives best thrust performance at cruise but it is noisy at LTO. A long conic plug, on the other hand, is quieter at LTO but may have unacceptable thrust at cruise.

jets↗
NASA NTRS1981

Aeroacoustics of a porous plug jet noise suppressor

The aeroacoustics of a porous plug jet noise suppressor was investigated. The predicted flow features of isentropic plug nozzles for different pressure ratios or exit flow Mach numbers, throat areas, ratios of the plug to annular nozzle radii, mass flow rates and the available run times possible with the existing compressed air supply system, are compiled. The dimensions and the coordinates of the contour of typical isentropic external expansion plugs with different exit flow Mach numbers are listed. Design details of the experimental facility and the plug nozzle selected for experimental aeroacoustic studies are reported. The analytical flow prediction by method of characteristics of a conical porous plug nozzles is initiated. The role of the shape, size, and porosity of the plug surface in achieving over a perforated conical plug a nearly isentropic shockfree supersonic flow field which is closely similar to the flow field of a contoured isentropic plug nozzle is examined.

Dosanjh, D. S.↗
NASA NTRS1999

Initial Study of Friction Pull Plug Welding

Pull plug friction welding is a new process being developed to conveniently eliminate defects from welded plate tank structures. The general idea is to drill a hole of precise, optimized dimensions and weld a plug into it, filling the hole perfectly. A conically-shaped plug is rotated at high angular velocity as it is brought into contact with the plate material in the hole. As the plug is pulled into the hole, friction rapidly raises the temperature to the point at which the plate material flows plastically. After a brief heating phase, the plug rotation is terminated. The plug is then pulled upon with a forging force, solidly welding the plug into the hole in the plate. Three aspects of this process were addressed in this study. The transient temperature distribution was analyzed based on slightly idealized boundary conditions for different plug geometries. Variations in hole geometry and ram speed were considered, and a program was created to calculate volumes of displaced material and empty space, as well as many other relevant dimensions. The relation between the axially applied forging force and the actual forging pressure between the plate and plug surfaces was determined for various configurations.

Rich, Brian S.↗
NASA NTRS2003

Comparison of Experimental Data and Computations Fluid Dynamics Analysis for a Three Dimensional Linear Plug Nozzle

A three dimensional linear plug nozzle of area ratio 12.79 was designed by EADS Space Transportation (former Astrium Space Infrastructure). The nozzle was tested within the German National Technology Program 'LION' in a cold air wind tunnel by TU Dresden. The experimental hardware and test conditions are described. Experimental data was obtained for the nozzle without plug side wall fences at a nozzle pressure ratio of 116 and then with plug side wall fences at NPR 110. Schlieren images were recorded and axial profiles of plug wall static pressures were measured at several spanwise locations and on the plug base. Detailed CFD analysis was performed for these nozzle configurations at NPR 116 by NASA MSFC. The CFD exhibits good agreement with the experimental data. A detailed comparison of the CFD results and the experimental plug wall pressure data are given. Comparisons are made for both the without and with plug side wall fence configurations. Numerical results for density gradient are compared to experimental Schlieren images. Experimental nozzle thrust efficiencies are calculated based on the CFD results. The CFD results are used to illustrate the plug nozzle fluid dynamics. The effect of the plug side wall is emphasized.

Ruf, J. H.↗
NASA NTRS2003

Comparison of Experimental Data and Computations Fluid Dynamics Analysis for a Three Dimensional Linear Plug Nozzle

A three dimensional linear plug nozzle of area ratio 12.79 was designed by Astrium. The nozzle was tested within the German National Technology Program LION in a cold air wind tunnel by TU Dresden. The experimental hardware and test conditions are described. Experimental data was obtained for the nozzle without plug side wall fences and then with plug side wall fences. Experimental data for two nozzle pressure ratios (NPR), 116 and 45, are presented for the without fence and with fence configurations. Schlieren images of both NPR were recorded. Axial profiles of plug wall static pressures were measured at several spanwise locations and on the plug base. Detailed computational fluid dynamics (CFD) analysis was performed for these nozzle configurations by NASA MSFC. The CFD exhibits good agreement with the experimental data. A detailed comparison of the CFD results and the experimental plug wall pressure data is given for four test conditions; at both NPRs, without and with plug side wall fences. Numerical schlieren images are compared to experimental schlieren images. Nozzle thrust efficiencies are calculated from the CFD results. The CFD results are used to illustrate the plug nozzle fluid dynamics for all four test conditions. The effect of the plug side wall fences at both NPRs is emphasized.

Ruf, J. H.↗