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Ryan, Daniel

Publications and source records attributed to Ryan, Daniel.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine

Modifying fossil-fueled industrial gas turbines to utilize low or zero-carbon fuels, such as hydrogen or hydrogen-natural gas blends, is a complex endeavor. The successful implementation of this technology hinges on three key design criteria: (1) developing new fuel injectors capable of efficiently burning alternative fuels, (2) ensuring manufacturability to meet cost and time-to-market goals, and (3) achieving component durability in the demanding environment of an operating gas turbine. Additive manufacturing (AM) accelerates product development, yet concerns persist regarding the durability of parts with rough AM surfaces. A fully experimental approach to quantify the fatigue performance of rough AM microstructures is both costly and labor-intensive. To address this, ORNL and Solar Turbines Incorporated (Solar) employed a crystal plasticity finite element (CPFE) model to identify the factors influencing AM surface fatigue behavior. These CPFE findings, combined with targeted experimental data, were used to develop a computationally efficient surrogate model suitable for assessing the lifespan of gas turbine engine components.

08 HYDROGEN↗
DOE OSTI2024

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine Combustion

Modification of fossil-fueled industrial gas turbines to accept no/low carbon fuels (Hydrogen, H2/natural gas blends) is a significant undertaking. Successful deployment of this technology sits at the intersection of three design criteria (1) new functional fuel injectors that can burn these fuels, (2) manufacturability to meet cost and time-to-market targets, and (3) durability in the harsh environment of an operating turbine. Additive manufacturing (AM) provides accelerated product development. However, uncertainty remains around the durability of parts with rough AM surfaces. A fully experimental approach towards quantifying fatigue performance of rough AM microstructures is costly and laborious. Instead, Solar Turbines Incorporated (Solar) proposes the use of a crystal plasticity finite element (CPFE) model to quantify the factors that drive AM surface fatigue behavior. Solar will use the CPFE results, along with targeted experimental data, to train a computationally efficient surrogate model that can be incorporated into existing turbine part lifing methods.

08 HYDROGEN↗
DOE OSTI2024

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

Additive Manufacturing (AM), also known as 3D printing, has emerged as a manufacturing method that enables new design freedom for gas turbine engine manufacturers. However, the material selection for AM processable high-temperature super alloys is currently limited. Additionally, the heat transfer performance of AM enabled micro-cooling architectures is not yet well understood. Accordingly, in support of advanced manufacturing and engine performance development, Oak Ridge National Laboratory (ORNL)and Solar Turbines (Solar) conducted a multidisciplinary project to generate both AM super alloy material properties data and micro-channel performance data for two AM super alloys. The data supported the design and analysis of an internally cooled turbine hot section AM tip shoe component. This data was used to analytically predict the reduction in operating temperature of a gas turbine tip shoe. The work concluded that the cooling flow required to cool the tip shoe can be tuned to suit the efficiency improvements desired in an industrial gas turbine.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Design of Novel Hot Gas Path Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This report covers the activities associated with the development and evaluation of two high-γ’ superalloys that were designed by external partners on this project, namely Carpenter Technologies Corporation and the University of California-Santa Barbra. One alloy was GammaPrint-700, a cobalt-base superalloy, and the other a nickel-base (Ni-base) superalloy GammaPrint-1100. Both were found to be printable through laser powder bed fusion (LPBF) additive manufacturing, with optimal process parameter sets being identified for each alloy. Further, high temperature mechanical testing was conducted on each alloy that showed both materials performed better than the comparative baseline (LPBF Hastelloy X), with the Ni-base superalloy being down-selected for scaling and printing of the tip shoe components.

36 MATERIALS SCIENCE↗
DOE OSTI2024

An expanded transcriptome atlas for Bacteroides thetaiotaomicron reveals a small RNA that modulates tetracycline sensitivity

Plasticity in gene expression allows bacteria to adapt to diverse environments. This is particularly relevant in the dynamic niche of the human intestinal tract; however, transcriptional networks remain largely unknown for gut-resident bacteria. Here we apply differential RNA sequencing (RNA-seq) and conventional RNA-seq to the model gut bacterium Bacteroides thetaiotaomicron to map transcriptional units and profile their expression levels across 15 in vivo-relevant growth conditions. We infer stress- and carbon source-specific transcriptional regulons and expand the annotation of small RNAs (sRNAs). Integrating this expression atlas with published transposon mutant fitness data, we predict conditionally important sRNAs. These include MasB, which downregulates tetracycline tolerance. Using MS2 affinity purification and RNA-seq, we identify a putative MasB target and assess its role in the context of the MasB-associated phenotype. These data—publicly available through the Theta-Base web browser (http://micromix.helmholtz-hiri.de/bacteroides/)—constitute a valuable resource for the microbiome community.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Impacts of Superalloys on the Surface Quality of Additively Manufactured Channels

Abstract Gas turbines feature many components that require superalloys capable of handling extreme thermal environments. Increasing the selection of materials available for these components is important to their use in these extremely high-temperature environments. This study investigated two recently developed materials intended to be used for additive manufacturing (AM), with one superalloy based on cobalt and the other on nickel. Sets of four test coupons were built using the materials, in addition to the commonly used Inconel-718, on multiple laser powder bed fusion machines. Several build conditions were varied between coupon sets, including coupon orientation, contour settings, and upskin and downskin treatment. Each set of test coupons featured four unique cooling designs to explore how different cooling technologies would be impacted by the variations in build conditions. After being built, coupons were computed tomography (CT) scanned to determine accuracy to design intent and quantify the surface roughness. The CT scans indicated that horizontally built test coupons had a significantly higher deviation from design intent and higher surface roughness than those built vertically. Results also indicated that the cobalt-based alloy consistently had a smoother surface quality with lower surface roughness compared to the nickel-based alloy. After geometric characterization, the cooling performance of the test coupons was measured experimentally. Pressure losses were found to correlate with increases in surface roughness; however, in some cases, the convective heat transfer did not increase proportionally to the pressure loss as a result of surface features significantly blocking the flow without proportionally increasing convective heat transfer.

Engineering↗
NASA NTRS2019

FOXSI-2 Solar Microflares: Multi-Instrument Differential Emission Measure Analysis

Outline: Overview of FOXSI-2 (Focusing Optics X-ray Solar Imager) coordinated microflare observations with Hinode/XRT (X-Ray Telescope) and SDO/AIA (Solar Dynamics Observatory/Atmospheric Imaging Assembly); Temperature response functions for FOXSI-2, XRT and AIA; Combined Differential Emission Measure (DEM) analysis - to determine the amount of plasma in the line of sight that emits the radiation as a function of temperature; Thermal energy released during the microflares; Summary.

Athiray, P. S.↗
NASA NTRS2017

Fabrication of coronagraph masks and laboratory scale star-shade masks: characteristics, defects and performance

NASA WFIRST mission has planned to include a coronagraph instrument to find and characterize exoplanets. Masks are needed to suppress the host star light to better than 10-8 – 10-9 level contrast over a broad bandwidth to enable the coronagraph mission objectives. Such masks for high contrast coronagraphic imaging require various fabrication technologies to meet a wide range of specifications, including precise shapes, micron scale island features, ultra-low reflectivity regions, uniformity, wave front quality, etc. We present the technologies employed at JPL to produce these pupil plane and image plane coronagraph masks, and lab-scale external occulter masks, highlighting accomplishments from the high contrast imaging testbed (HCIT) at JPL and from the high contrast imaging lab (HCIL) at Princeton University. Inherent systematic and random errors in fabrication and their impact on coronagraph performance are discussed with model predictions and measurements.

Casey Wilson, Robert↗
NASA NTRS2016

The HEXITEC Hard X-Ray Pixelated CdTe Imager for Fast Solar Observations

There is an increasing demand in solar and astrophysics for high resolution X-ray spectroscopic imaging. Such observations would present ground breaking opportunities to study the poorly understood high energy processes in our solar system and beyond, such as solar flares, X-ray binaries, and active galactic nuclei. However, such observations require a new breed of solid state detectors sensitive to high energy X-rays with fine independent pixels to sub-sample the point spread function (PSF) of the X-ray optics. For solar observations in particular, they must also be capable of handling very high count rates as photon fluxes from solar flares often cause pile up and saturation in present generation detectors. The Rutherford Appleton Laboratory (RAL) has recently developed a new cadmium telluride (CdTe) detector system, called HEXITEC (High Energy X-ray Imaging Technology). It is an 80 x 80 array of 250 micron independent pixels sensitive in the 2-200 keV band and capable of a high full frame read out rate of 10 kHz. HEXITEC provides the smallest independently read out CdTe pixels currently available, and are well matched to the few arcsecond PSF produced by current and next generation hard X-ray focusing optics. NASA's Goddard and Marshall Space Flight Centers are collaborating with RAL to develop these detectors for use on future space borne hard X-ray focusing telescopes. We show the latest results on HEXITEC's imaging capability, energy resolution, high read out rate, and reveal it to be ideal for such future instruments.

Baumgartner, Wayne H.↗
NASA NTRS2015

Laboratory Performance of the Shaped Pupil Coronagraphic Architecture for the WFIRST-AFTA Coronagraph

One of the two primary architectures being tested for the WFIRST-AFTA coronagraph instrument is the shaped pupil coronagraph, which uses a binary aperture in a pupil plane to create localized regions of high contrast in a subsequent focal plane. The aperture shapes are determined by optimization, and can be designed to work in the presence of secondary obscurations and spiders-an important consideration for coronagraphy with WFIRSTAFTA. We present the current performance of the shaped pupil testbed, including the results of AFTA Milestone 2, in which approximately 6 × 10(exp −9) contrast was achieved in three independent runs starting from a neutral setting.

Cady, Eric↗
NASA NTRS2015

Exoplanet Coronagraph Shaped Pupil Masks and Laboratory Scale Star Shade Masks: Design, Fabrication and Characterization

Star light suppression technologies to find and characterize faint exoplanets include internal coronagraph instruments as well as external star shade occulters. Currently, the NASA WFIRST-AFTA mission study includes an internal coronagraph instrument to find and characterize exoplanets. Various types of masks could be employed to suppress the host star light to about 10 -9 level contrast over a broad spectrum to enable the coronagraph mission objectives. Such masks for high contrast internal coronagraphic imaging require various fabrication technologies to meet a wide range of specifications, including precise shapes, micron scale island features, ultra-low reflectivity regions, uniformity, wave front quality, achromaticity, etc. We present the approaches employed at JPL to produce pupil plane and image plane coronagraph masks by combining electron beam, deep reactive ion etching, and black silicon technologies with illustrative examples of each, highlighting milestone accomplishments from the High Contrast Imaging Testbed (HCIT) at JPL and from the High Contrast Imaging Lab (HCIL) at Princeton University. We also present briefly the technologies applied to fabricate laboratory scale star shade masks.

black silicon↗
NASA NTRS2010

Measuring Cyclic Error in Laser Heterodyne Interferometers

An improved method and apparatus have been devised for measuring cyclic errors in the readouts of laser heterodyne interferometers that are configured and operated as displacement gauges. The cyclic errors arise as a consequence of mixing of spurious optical and electrical signals in beam launchers that are subsystems of such interferometers. The conventional approach to measurement of cyclic error involves phase measurements and yields values precise to within about 10 pm over air optical paths at laser wavelengths in the visible and near infrared. The present approach, which involves amplitude measurements instead of phase measurements, yields values precise to about .0.1 microns . about 100 times the precision of the conventional approach. In a displacement gauge of the type of interest here, the laser heterodyne interferometer is used to measure any change in distance along an optical axis between two corner-cube retroreflectors. One of the corner-cube retroreflectors is mounted on a piezoelectric transducer (see figure), which is used to introduce a low-frequency periodic displacement that can be measured by the gauges. The transducer is excited at a frequency of 9 Hz by a triangular waveform to generate a 9-Hz triangular-wave displacement having an amplitude of 25 microns. The displacement gives rise to both amplitude and phase modulation of the heterodyne signals in the gauges. The modulation includes cyclic error components, and the magnitude of the cyclic-error component of the phase modulation is what one needs to measure in order to determine the magnitude of the cyclic displacement error. The precision attainable in the conventional (phase measurement) approach to measuring cyclic error is limited because the phase measurements are af-

Ryan, Daniel↗
NASA NTRS2007

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗
NASA NTRS2006

Measurement of the Non-common Vertex Error of a Double Corner Cube

The Space Interferometry Mission (SIM) requires the control of the optical path of each interferometer with picometer accuracy. Laser metrology gauges are used to measure the path lengths to the fiiducial corner cubes at the siderostats. Due to the geometry of SIM a single corner cube does not have sufficient acceptance angle to work with all the gauges. Therefore SIM employs a double corner cube. Current fabrication methods are in fact not capable of producing such a double corner cube with vertices having sufficient commonality. The plan for SIM is to measure the non-commonalty of the vertices and correct for the error in orbit. SIM requires that the non-common vertex error (NCVE) of the double corner cube to be less than 6 (mu)m. The required accuracy for the knowledge of the NCVE is less than 1 (mu)m. This paper explains a method of measuring non-common vertices of a brassboard double corner cube with sub-micron accuracy. The results of such a measurement will be presented.

Space Interferometry Mission (SIM)↗
NASA NTRS2006

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced nondestructive evaluation (NDE) techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter's wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗
NASA NTRS2006

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter's wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗