Results for “High Temperature Test Facility” — Page 12

DOE OSTI2025

Current Progress on the High-Field Cable Testing Facility at Fermilab

Fermi National Accelerator Laboratory (Fermilab) is constructing a new High Field Vertical Magnet Test Facility (HFVMTF) with capabilities comparable to the European facilities EDIPO and FRESCA2. The facility, located at Fermilab, will feature a background magnetic field of 15 T, generated by a magnet provided by Lawrence Berkeley National Laboratory (LBNL). The HFVMTF will support two U.S. national programs under the DOE Office of Science: the U.S. Fusion Energy Science (FES) program and the Magnet Development Program (MDP). It will enable the testing of HTS samples in high magnetic fields across a wide range of temperatures and facilitate the development of hybrid magnets combining LTS and HTS superconductors. This paper presents an overview of the current progress in constructing the facility, including updates on the test cryostat, power supplies, and systems for quench protection and monitoring.

Velev, G. [Fermilab]↗

DOE OSTI2023

Engineering-Scale Integrated Energy System Data Projection Demonstration via the Dynamic Energy Transport and Integration Laboratory

The objective of this study is to demonstrate and validate the Dynamic Energy Transport and Integration Laboratory (DETAIL) preliminary scaling analysis using Modelica language system-code Dymola. The DETAIL preliminary scaling analysis includes a multisystem integral scaling package between thermal-storage and hydrogen-electrolysis systems. To construct the system of scaled equations, dynamical system scaling (DSS) was applied to all governing laws and closure relations associated with the selected integral system. The existing Dymola thermal-energy distribution system (TEDS) facility and high-temperature steam electrolysis (HTSE) facility models in the Idaho National Laboratory HYBRID repository were used to simulate a test case and a corresponding scaled case for integrated system HYBRID demonstration and validation. The DSS projected data based on the test-case simulations and determined scaling ratios were generated and compared with scaled case simulations. The preliminary scaling analysis performance was evaluated, and scaling distortions were investigated based on data magnitude, sequence, and similarity. The results indicated a necessity to change the normalization method for thermal storage generating optimal operating conditions of 261 kW power and mass flow rate of 6.42 kg/s and the possibility of reselecting governing laws for hydrogen electrolysis to improve scaling predictive properties. To enhance system-scaling similarity for TEDS and HTSE, the requirement for scaling validation via physical-facility demonstration was identified.

08 HYDROGEN↗

NASA NTRS1993

Development of thin film thermocouples on ceramic materials for advanced propulsion system applications

Thin film thermocouples were developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hr or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, Raymond↗

NASA NTRS1992

Development of Thin Film Thermocouples on Ceramic Materials for Advanced Propulsion System Applications

Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 c. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperature of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, R.↗

NASA NTRS1992

Thin film thermocouples for high temperature measurement on ceramic materials

Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high-heating-rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, Raymond↗

DOE OSTI2024

Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing

Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2015

Development of Background-Oriented Schlieren for NASA Langley Research Center Ground Test Facilities

This paper provides an overview of recent wind tunnel tests performed at the NASA Langley Research Center where the Background-Oriented Schlieren (BOS) technique was used to provide information pertaining to flow-field density disturbances. The facilities in which the BOS technique was applied included the National Transonic Facility (NTF), Transonic Dynamics Tunnel (TDT), 31-Inch Mach 10 Air Tunnel, 15-Inch Mach 6 High-Temperature Air Tunnel, Rotor Test Cell at the 14 by 22 Subsonic Tunnel, and a 13-Inch Low-Speed Tunnel.

Bathel, Brett F.↗

NASA NTRS1995

Initial results from the Solar Dynamic (SD) Ground Test Demonstration (GTD) project at NASA Lewis

A government/industry team designed, built, and tested a 2 kWe solar dynamic space power system in a large thermal/vacuum facility with a simulated sun at the NASA Lewis Research Center. The Lewis facility provides an accurate simulation of temperatures, high vacuum, and solar flux as encountered in low earth orbit. This paper reviews the goals and status of the Solar Dynamic (SD) Ground Test Demonstration (GTD) program and describes the initial testing, including both operational and performance data. This SD technology has the potential as a future power source for the International Space Station Alpha.

Shaltens, Richard K.↗

DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗

NASA NTRS1995

A Heated Tube Facility for Rocket Coolant Channel Research

The capabilities of a heated tube facility used for testing rocket engine coolant channels at the NASA Lewis Research Center are presented. The facility uses high current, low voltage power supplies to resistively heat a test section to outer wall temperatures as high as 730 C (1350 F). Liquid or gaseous nitrogen, gaseous helium, or combustible liquids can be used as the test section coolant. The test section is enclosed in a vacuum chamber to minimize heat loss to the surrounding system. Test section geometry, size, and material; coolant properties; and heating levels can be varied to generate heat transfer and coolant performance data bases.

Green, James M.↗

NASA NTRS2002

Application of DPIV to Enhanced Mixing Heated Nozzle Flows

Digital Particle Imaging Velocimetry (DPIV) is a planar velocity measurement technique that continues to be applied to new and challenging engineering research facilities while significantly reducing facility test time. DPIV was used in the GRC Nozzle Acoustic Test Rig (NATR) to characterize the high temperature (560 C), high speed (is greater than 500 m/s) flow field properties of mixing enhanced jet engine nozzles. The instantaneous velocity maps obtained using DPIV were used to determine mean velocity, rms velocity and two-point correlation statistics to verify the true turbulence characteristics of the flow. These measurements will ultimately be used to properly validate aeroacoustic model predictions by verifying CFD input to these models. These turbulence measurements have previously not been possible in hot supersonic jets. Mapping the nozzle velocity field using point based techniques requires over 60 hours of test time, compared to less than 45 minutes using DPIV, yielding a significant reduction in testing time. A dual camera DPIV configuration was used to maximize the field of view and further minimize the testing time required to map the nozzle flow. The DPIV system field of view covered 127 by 267 mm. Data were acquired at 19 axial stations providing coverage of the flow from the nozzle exit to 2.37 in downstream. At each measurement station, 400 image frame pairs were acquired from each camera. The DPIV measurements of the mixing enhanced nozzle designs illustrate the changes in the flow field resulting in the reduced noise signature.

Wernet, Mark P.↗

NASA NTRS1986

Unified constitutive materials model development and evaluation for high-temperature structural analysis applications

Unified constitutive material models were developed for structural analyses of aircraft gas turbine engine hot section components with particular application to an isotropic material used for combustor liners. Differential forms of models independently developed were considered in this study. These models combine the interactions of time-dependent (creep) and time-independent (plasticity) inelastic behavior of a material. Predicted stress-strain responses from these models were evaluated against cyclic isothermal and nonisothermal test results for uniaxial specimens of a nickel-base superalloy. The unified models were implemented in a nonlinear structural analysis code. Two unique NASA Lewis test facilities were used in the evaluation of the models for complex geometry specimens and evaluation of advanced temperature and high-temperature strain measurement instrumentation. Predicted nonlinear structural responses from one of the models for a flat plate and a segment of a conventional combustor liner are presented.

Thompson, R. L.↗

DOE OSTI2022

Assessment of ASI-developed Sensors for Inclusion in METL Testing

The Advanced Sensors and Instrumentation (ASI) program facilitates the development of new sensors for both conventional and advanced reactors. Advanced reactor concepts utilize coolants other than light water, such as molten salts, liquid sodium, and high-temperature helium. Qualification of sensors developed for these advanced reactors is complicated by the relatively small number of facilities available that can provide relevant testing conditions (e.g., temperature, flow, and coolant chemistry). This report identifies sensors that were developed under the ASI program and may be tested in one available testbed: the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL), a non-nuclear liquid sodium flow facility.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2017

Rotational Raman-Based Temperature Measurements in a High-Velocity Turbulent Jet

Spontaneous rotational Raman scattering spectroscopy is used to acquire the first ever high quality, spatially-resolved measurements of the mean and root mean square (rms) temperature fluctuations in turbulent, high-velocity heated jets. Raman spectra in air were obtained across a matrix of radial and axial locations downstream from a 50 mm diameter nozzle operating from subsonic to supersonic conditions over a wide range of temperatures and Mach numbers, in accordance with the Tanna matrix frequently used in jet noise studies. These data were acquired in the hostile, high noise (115 dB) environment of a large scale open air test facility at NASA Glenn Research Center (GRC). Temperature estimates were determined by performing nonlinear least squares fitting of the single shot spectra to the theoretical rotational Stokes spectra of N2 and O2, using a custom in-house code developed specifically for this investigation. The laser employed in this study was a high energy, long-pulsed, frequency doubled Nd:YAG laser. One thousand single-shot spectra were acquired at each spatial coordinate. Mean temperature and rms temperature variations were calculated at each measurement location. Excellent agreement between the averaged and single-shot temperatures was observed with an accuracy better than 2.5 percent for temperature, and rms variations in temperature between +/-2.2 percent at 296 K and +/-4.5 percent at 850 K. The results of this and planned follow-on studies will support NASA GRC's development of physics-based jet noise prediction, turbulence modeling and aeroacoustic source modeling codes.

Randy J Locke↗

NASA NTRS2017

Rotational Raman-Based Temperature Measurements in a High-Velocity Turbulent Jet

Spontaneous rotational Raman scattering spectroscopy is used to acquire the first ever high quality, spatially-resolved measurements of the mean and root mean square (rms) temperature fluctuations in turbulent, high-velocity heated jets. Raman spectra in air were obtained across a matrix of radial and axial locations downstream from a 50 mm diameter nozzle operating from subsonic to supersonic conditions over a wide range of temperatures and Mach numbers, in accordance with the Tanna matrix frequently used in jet noise studies. These data were acquired in the hostile, high noise (115 dB) environment of a large scale open air test facility at NASA Glenn Research Center (GRC). Temperature estimates were determined by performing nonlinear least squares fitting of the single shot spectra to the theoretical rotational Stokes spectra of N2 and O2, using a custom in-house code developed specifically for this investigation. The laser employed in this study was a high energy, long-pulsed, frequency doubled Nd:YAG laser. One thousand single-shot spectra were acquired at each spatial coordinate. Mean temperature and rms temperature variations were calculated at each measurement location. Excellent agreement between the averaged and single-shot temperatures was observed with an accuracy better than 2.5 percent for temperature, and rms variations in temperature between +/-2.2 percent at 296 K and +/-4.5 percent at 850 K. The results of this and planned follow-on studies will support NASA GRC's development of physics-based jet noise prediction, turbulence modeling and aeroacoustic source modeling codes.

Randy J Locke↗

NASA NTRS2008

Compliant Foil Journal Bearing Performance at Alternate Pressures and Temperatures

An experimental test program has been conducted to determine the highly loaded performance of current generation gas foil bearings at alternate pressures and temperatures. Typically foil bearing performance has been reported at temperatures relevant to turbomachinery applications but only at an ambient pressure of one atmosphere. This dearth of data at alternate pressures has motivated the current test program. Two facilities were used in the test program, the ambient pressure rig and the high pressure rig. The test program utilized a 35 mm diameter by 27 mm long foil journal bearing having an uncoated Inconel X-750 top foil running against a shaft with a PS304 coated journal. Load capacity tests were conducted at 3, 6, 9, 12, 15, 18, and 21 krpm at temperatures from 25 to 500 C and at pressures from 0.1 to 2.5 atmospheres. Results show an increase in load capacity with increased ambient pressure and a reduction in load capacity with increased ambient temperature. Below one-half atmosphere of ambient pressure a dramatic loss of load capacity is experienced. Additional lightly loaded foil bearing performance in nitrogen at 25 C and up to 48 atmospheres of ambient pressure has also been reported. In the lightly loaded region of operation the power loss increases for increasing pressure at a fixed load. Knowledge of foil bearing performance at operating conditions found within potential machine applications will reduce program development risk of future foil bearing supported turbomachines.

Bruckner, Robert J.↗

NASA NTRS2008

Compliant Foil Journal Bearing Performance at Alternate Pressures and Temperatures

An experimental test program has been conducted to determine the highly loaded performance of current generation gas foil bearings at alternate pressures and temperatures. Typically foil bearing performance has been reported at temperatures relevant to turbomachinery applications but only at an ambient pressure of one atmosphere. This dearth of data at alternate pressures has motivated the current test program. Two facilities were used in the test program, the ambient pressure rig and the high pressure rig. The test program utilized a 35 mm diameter by 27 mm long foil journal bearing having an uncoated Inconel X-750 top foil running against a shaft with a PS304 coated journal. Load capacity tests were conducted at 3, 6, 9, 12, 15, 18, and 21 krpm at temperatures from 25 to 500 C and at pressures from 0.1 to 2.5 atmospheres. Results show an increase in load capacity with increased ambient pressure and a reduction in load capacity with increased ambient temperature. Below one-half atmosphere of ambient pressure a dramatic loss of load capacity is experienced. Additional lightly loaded foil bearing performance in nitrogen at 25 C and up to 48 atmospheres of ambient pressure has also been reported. In the lightly loaded region of operation the power loss increases for increasing pressure at a fixed load. Knowledge of foil bearing performance at operating conditions found within potential machine applications will reduce program development risk of future foil bearing supported turbomachines.

Bruckner, Robert J.↗

NASA NTRS1992

High pressure hypervelocity electrothermal wind tunnel performance study and subscale tests

The feasibility of a Mach 10 to 20, high pressure electrothermal wind tunnel was assessed. A heater based on a continuous high power electric arc discharge capable of heating air to temperatures above 10,000 K and pressures of 15,000 atm is the key element of this wind tunnel. Results of analytical study indicate that the facility is capable of simulation conditions suitable for hypervelocity airbreathing propulsion testing up to Mach 16. In this case simulation was limited by pressure containment, high nozzle throat heat flux rates, and chemical freezing in the nozzle. The high total pressure capability improved the recombination chemistry in the facility nozzle as chemical equilibrium prevailed to the freezing point. Steady arc discharges were observed with liquid nitrogen flowing into the arc chamber during tests based on the two millisecond test facility. The measured steady pressure in the arc chamber was 4559 psi, which is two times greater than maximum total pressure obtainable in conventional arc heaters.

Rizkalla, Oussama F.↗