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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Conversion, Stability, and Selectivity Improvements Through Catalyst Development for the Reductive Etherification Reaction

Economical pathways from lignocellulosic non-food biomass feedstocks to biofuels with appropriate fuel properties are necessary for displacing fossil-fuel derived diesel use in medium-/heavy duty vehicles. Oxygenated compounds have recently shown promise due to low sooting tendencies and autoignition properties and molecules with sufficiently high carbon numbers can meet the requisite standards for water solubility and flash point. Coupling waste biomass derived small molecules into bioblendstock targets through the reductive etherification reaction shows potential for increasing molecular weight without losing the advantages of oxygenates. However, the transition to industrial viability for this process is limited by strong catalyst deactivation in typical flow reactor systems. Strong acid resins such as Amberlyst-15 (A-15) show excellent activity in batch reactions but are limited to low temperatures and are poisoned by the side-product, water. In this talk, I will describe our recent work in catalyst synthesis and testing to select superior options with improved aqueous and thermal stability in reductive etherification flow reactions. Water-tolerant solid acid catalysts have potential to improve the conversion and selectivity to the ether target at temperatures above the degradation point of A-15. Analysis techniques such as physisorption, chemisorption, x-ray diffraction and transmission electron microscopy are being used to characterize the active sites. These techniques are also being used to evaluate degradation of the catalyst after extensive flow reactions in addition to comparative efficiency testing with standardized cyclohexene hydrogenation reactions. Finally, I will discuss a demonstration of the full pathway from bio-derived butyric acid to the performance-advantaged ether product and the additional obstacles from side-products and purification limitations in the preliminary upgrading reactions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

The Influence of Processing Parameters on the Transition Zone for Blended Material 3D Printing

The use of Multiple Materials (MM) in Additive Manufacturing (AM) is increasingly important for expanding the range of applications in the manufacturing industry, particularly for large-format processes. Typically, polymer-based AM incorporates MM transitions through discrete interfaces between layers. This arrangement significantly increases the occurrence of layer delamination failures due to decreased bonding between dissimilar polymers. Elimination of discrete material interfaces by continuously transitioning from Material A to B provides a possible solution. Such continuous gradients could be used to create functionally graded structures that take full advantage of AM’s capability to deliberately impart site-specific properties. Cincinnati’s Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Lab has been equipped with a dual-hopper system that enables in-situ material switching specifically intended for functionally graded and MM printing. The resulting material transition exhibits varied behavior based on printing conditions, which can have an impact on part design and resulting mechanical properties. In this work, the transition zone is characterized as a function of the printing screw speed (related to volumetric flow) and the screw geometry.

Brackett, James↗
DOE OSTI2022

Large eddy simulation of flow through an axisymmetric sudden expansion

Here, this study aims at investigating the inlet flow conditions of flow through an axisymmetric sudden expansion with an expansion ratio of 2.0. A series of large eddy simulations with the WALE model were conducted for different inlet Reynolds numbers ( Re) and turbulence intensities ($u_{rms}/\bar{U}_m$). The reattachment length, defined as the length measured downstream of the expansion where the flow direction is reversed adjacent to the wall ( Lr), was measured for each case. For widely studied inlet turbulence intensity values (TI), the simulation results are in good agreement with the experimental and numerical results reported in the literature. Parametric studies revealed that turbulence intensity affects the critical Reynolds number, marking the transition between the laminar and transition regions and the reattachment length. The critical Reynolds number was found to decrease with increasing turbulence intensity. A correlation expression is proposed. Additional analysis with proper orthogonal decomposition was performed to enhance the understanding of complex flow structures downstream of the expansion. Finally, an overall correlation expression for the reattachment length was obtained for 500 ≤ Re ≤15 000 and 0.2 ≤ TI (%) ≤ 20. For a given turbulence intensity, the reattachment length can be expressed for laminar and turbulent regions as a function of the Reynolds number. The reattachment length in the transition region can be expressed as a fractional average of reattachment lengths for laminar and turbulent flows.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2021

Hydrokinetic Energy Conversion by Flow-Induced Oscillation of Two Tandem Cylinders of Different Stiffness

Abstract The vortex-induced vibration for aquatic clean energy (VIVACE) converter harnesses hydrokinetic energy by enhancing flow-induced oscillations (FIOs) of elastically supported rigid cylinders in a river, tide, or ocean current. The harnessing power depends on the intensity of the oscillation, which is a consequence of the flow–structure interaction. The inflow condition for the downstream (second) cylinder is slowed down and perturbed by the upstream (first) cylinder, due to the shielding effect. Therefore, the optimal structural parameters, i.e., stiffness and damping ratio, for the second cylinder may be different from the first cylinder, in terms of energy harnessing. To improve the performance of the VIVACE converter, a series of experiments are conducted in a recirculating water channel, with various stiffness combinations of two cylinders in tandem. Results show that the stiffness of the second cylinder, K2, does not affect the energy harnessing power in vortex-induced vibration (VIV) occurring at low speeds, because the oscillation of the downstream cylinder in this velocity range is completely dominated by the wake of the upstream cylinder. K2 has a great influence on the harnessing power at higher velocities in the transition region from VIV to galloping and in galloping. Changing K2 onsets and enhances galloping at lower flow velocity and harnesses up to 110% more energy than the case of K1 = K2.

Engineering↗
DOE OSTI2024

Antecedent Hydrologic Conditions Reflected in Stream Lithium Isotope Ratios During Storms

Antecedent hydrological conditions are recorded through the evolution of dissolved lithium isotope signatures (δ 7 Li) by juxtaposing two storm events in an upland watershed subject to a Mediterranean climate. Discharge and δ 7 Li are negatively correlated in both events,but mean δ 7 Li ratios and associated ranges of variation are distinct between them. We apply a previously developed reactive transport model (RTM) for the site to these event-scale flow perturbations, but observed shifts in stream δ 7 Li are not reproduced. To reconcile the stability of the subsurface solute weathering profile with our observations of dynamic stream δ 7 Li signatures, we couple the RTM to a distribution of fluid transit times that evolve based on storm hydrographs. The approach guides appropriate flux-weighting of fluid from the RTM over a range of flow path lengths, or equivalently fluid residence times. This flux-weighted RTM approach accurately reproduces dynamic storm δ 7 Li-discharge patterns distinguished by the antecedent conditions of the watershed.

58 GEOSCIENCES↗
DOE OSTI2022

Charge Separation in Monolayer WSe 2 by Strain Engineering: Implications for Strain-Induced Diode Action

Strain-engineering band structure in transition-metal dichalcogenides (TMDC) is a promising avenue toward capabilities in optoelectronics. For example, controlling the flow of optically generated quasiparticles can be achieved by a localized strain field which reduces the bandgap and generates an energy-band gradient that funnels neutral excitons to the strain apex. It would be even more advantageous to mimic a diode’s internal field, where both conduction and valence bands bend in the same direction, to separate electrons and holes. This can be achieved if the strain in the TMDC layer lowers both the conduction band minimum as well as the valence band maximum during strain-induced band narrowing. Here, we have used density functional theory (DFT) calculations of monolayer WSe 2 electronic structure under biaxial strain to show that WSe 2 has this property. In this work, to test the band bending experimentally, we combined localized strain with electrostatic doping to follow photoluminescence from excitons and positive or negative trions. In unstrained WSe 2 , both positive and negative trion emissions dominate over excitons away from charge neutrality. In contrast, for strained areas, negative trions accumulate, while positive trion emission is near zero away from charge neutrality, indicating a lack of holes. Hence, strain bends both conduction and valence bands down, similarly to the band bending in a PN-diode depletion region, providing an opportunity to separate electrons and holes via localized strain.

2D materials↗
DOE OSTI2022

Evolution of Droplet Size Distributions During the Transition of an Ultraclean Stratocumulus Cloud System to Open Cell Structure: An LES Investigation Using Lagrangian Microphysics

Here, a state-of-the-art Lagrangian microphysics scheme is used in a large-eddy simulation to investigate the stratocumulus transition from closed to open cell structure. Processes controlling precipitation development, which is a key to the transition, are analyzed by leveraging unique benefits of Lagrangian microphysics, particularly the ability to track computational drops in the flow. Sufficient time is needed for coalescence growth of cloud drops to drizzle within the updraft-downdraft cycle of large eddies. This favors broad drop size distributions (DSDs) and drizzle growth in downdrafts, where drops are typically much older than in updrafts. During the closed cell stage, mean cloud drop radius is too small, and the DSDs are too narrow, so that the timescale for coalescence is much longer than the large eddy turnover time and drizzle growth is limited. The closed-to-open cell transition occurs when these timescales become comparable and the precipitation flux increases sharply.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Data and script associated with “Shifts in Rain-Snow Partitioning Drive Faster Water Transit Times in the US Pacific Northwest”

This data package contains the data and code to use and run the Water Tracer enabled version of the Weather Research and Forecasting Hydrologic model (WT-WRF-Hydro) with the Sequential Precipitation Input Tagging (SPIT) framework. It is associated with the publication “Shifts in Rain-Snow Partitioning Drive Faster Water Transit Times in the US Pacific Northwest” published in Scientific Reports (Butler et al., 2026; https://doi.org/10.1038/s41598-026-46539-1). We use the Continental U.S. (CONUSII; Rasmussen et al., 2021) dataset to force the model with an historical climate (2006–2013) and a future climate (2086–2093) with a representative carbon pathway (RCP) 8.5 scenario. We use the model to calculate water transit times in five headwater catchments within the U.S. Pacific Northwest. We also show key hydrologic and environmental variables that affect water transit times and changes in the future. Finally, we use observed data to validate the model such as stream water isotopes, snowpack characteristics, and stream discharge. For details on how to navigate data packages generated by this project, see https://data.ess-dive.lbl.gov/portals/PNNLRiverCorridorSFA/About. In addition to a readme, this data package also includes a file-level metadata (FLMD) file that describes each file and a data dictionary (DD) that describes all column/row headers and variable definitions. The data package consists of 11 folders: (1) "Figures" contains the exported figures used in the manuscript; (2) "Model_Isotope_Date" contains the WT-WRF-Hydro isotope date used in model validation; (3) “Model_Outputs_Future” contains the WT-WRF-Hydro future climate outputs; (4) “Model_Outputs_Historical” contains the WT-WRF-Hydro historical climate outputs; (5) “Model_Outputs_Weights_Areas” contains the WT-WRF-Hydro weights per catchment used to calculate water transit times and isotopes in stream water; (6) “MODIS_data_scripts” contains data used to validate snow conditions in the study area; (7) “Observed_Flow_Data” contains the observed streamflow data used in model validation; (8) “Observed_Isotope_Data” contains the observed stream water isotope data used in model validation; (9) “Scripts” contains the Python scripts used to general results and the figures; (10) “Statistic_Outputs” contains the water transit time statistical outputs reported in this manuscript; (11) “Validation_SNOTEL” contains the SNOTEL data used in model validation. The files in this data package have the following file extensions: .tif, .txt, .csv, .pdf, .py, .jpg, and .png.

American River↗
DOE OSTI2024

Quantifying Dissolution Dynamics in Porous Media Using a Spatial Flow Focusing Profile

Abstract The diverse range of patterns in porous media formed by dissolution processes depends on the relative magnitude of flow, transport, and chemical reactions at pore surfaces. However, distinguishing between regimes often relies solely on qualitative, visual comparisons of emergent structures. Here, we propose a quantitative measure capable of identifying different regimes using the concept of the spatial flow focusing profile, which segments the medium into cross sections along the flow direction to calculate the flow focusing index for each section. We employ this measure in numerical simulations of a dissolving porous medium using a pore network model. We obtain a morphological phase diagram of dissolution patterns, which we characterize using the flow focusing profile. In particular, we demonstrate that analyzing the temporal changes in the profile allows one to quantitatively distinguish between wormholing and channeling. The transition between them is shown to be affected by the heterogeneity of the system.

58 GEOSCIENCES↗
DOE OSTI2022

On the enhancement of boundary layer skin friction by turbulence: an angular momentum approach

Turbulence enhances the wall shear stress in boundary layers, significantly increasing the drag on streamlined bodies. Other flow features such as free stream pressure gradients and streamwise boundary layer growth also strongly influence the local skin friction. In this paper, an angular momentum integral (AMI) equation is introduced to quantify these effects by representing them as torques that alter the shape of the mean velocity profile. This approach uniquely isolates the skin friction of a Blasius boundary layer in a single term that depends only on the Reynolds number most relevant to the flow's engineering context, so that other torques are interpreted as augmentations relative to the laminar case having the same Reynolds number. The AMI equation for external flows shares this key property with the so-called FIK relation for internal flows (Fukagata et al. , Phys. Fluids , vol. 14, 2002, pp. L73–L76). Without a geometrically imposed boundary layer thickness, the length scale in the Reynolds number for the AMI equation may be chosen freely. After a brief demonstration using Falkner–Skan boundary layers, the AMI equation is applied as a diagnostic tool on four transitional and turbulent boundary layer direct numerical simulation datasets. Regions of negative wall-normal velocity are shown to play a key role in limiting the peak skin friction during the late stages of transition, and the relative strengths of terms in the AMI equation become independent of the transition mechanism a very short distance into the fully turbulent regime. The AMI equation establishes an intuitive, extensible framework for interpreting the impact of turbulence and flow control strategies on boundary layer skin friction.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

On falling film evaporator – A review of mechanisms and critical assessment of correlation on a horizontal tube bundle with updated development

Optimization of the energy efficiency and reduction of the greenhouse gas emission for the heat pump system is imperative to meet the net-zero goals at 2050. Chillers with falling film evaporator design not only possess better system performance but also contain less refrigerant inventory. Hence, accurate prediction of the evaporator performance is pivotal especially when charged with low-GWP refrigerant. Here, the study reviews the correlations for falling film evaporator with a horizontal tube bundle configuration. The major efforts of this study include four tasks: (a) literature review of the experimental studies and available empirical correlations; (b) comprehensive discussion of the falling film evaporation heat transfer mechanism; (c) development of a new rationally based correlation based on available literature; and (d) comparison of different correlations based on the existing data. The collected data includes 4114 data points from 8 sources, 6 refrigerants (R-600a, R-290, R-245fa, R-134a, R-1234ze(E), R-123), 5 types of the tubes (Plain, Turbo-GII-HP, GEWA-B, Low-fin, High-Flux), liquid Weber number from 2.2 × 10 –6 to 0.7, imposed vapor Weber number from 0 to 37.2, heat flux from 2.5 to 151.5 kW/m 2 , and film Reynolds number from 1 to 3159.8. The new correlation gives a MAD of 28.3%, and an R 2 of 0.86. Yet, the developed correlation considers various heat transfer mechanisms, including the transition point from falling film evaporation to the nucleate boiling, local evaporation, dry-out, mist flow, imposed flow, and enhanced tube effects.

42 ENGINEERING↗
DOE OSTI2026

Slow-Light Mid-IR Silicon Photonic Chips for NO 2 and CH 4 Gas Detection

A compact, chip-scale mid-infrared gas sensor is demonstrated, leveraging a two-dimensional photonic crystal waveguide (PCW) fabricated on a silicon-on-insulator (SOI) platform. The PCW comprises a hexagonal lattice with lattice constant a = 860 nm and hole radius r = 0.22a, incorporating a central line defect of reduced-radius holes (r s = 0.7r) to induce slow-light propagation near the photonic band edge with a group index of approximately 73, thereby enhancing light-matter interaction. The sensor operates at fundamental absorption wavelengths of 3.42 μm for nitrogen dioxide (NO 2 ) and 3.40 μm for methane (CH 4 ), utilizing the strongest molecular vibrational transitions for maximum sensitivity. Experimental validation was conducted using dynamically diluted gas mixtures generated by mass flow controllers, with signal acquisition performed by a liquid nitrogen-cooled InSb detector. For NO 2 , the sensor exhibited excellent linear response over 5–25 ppm (part per million) with coefficient of determination R 2 = 0.9934, achieving a detection limit of 210 ppb (part per billion)─representing the first reported silicon photonic-based NO 2 detection. For CH 4 , exposure to 25 ppm resulted in a 6.4% decrease in transmitted intensity, demonstrating multigas sensing capability. The CMOS-compatible fabrication process and compact 3 mm device footprint establish this SOI-PCW platform as a scalable, low-power solution for integrated mid-infrared gas sensing, with significant potential for environmental monitoring and industrial safety applications.

Crystals↗
DOE OSTI2021

Symmetry-Breaking Design of an Organic Iron Complex Catholyte for a Long Cyclability Aqueous Organic Redox Flow Battery

The limited availability of a high-performance catholyte has hindered development of aqueous organic redox flow batteries (AORFB) that are environmentally benign, have tunable structures, and are safer than their traditional transition metal ion-based counterparts for large-scale energy storage. In this paper, a symmetry-breaking design of iron complexes with 2,2’-bipyridine-4,4’-dicarboxylic (Dcbpy) acid and cyanide ligands is described. By introducing two ligands to the metal center, the complex compounds (M4[FeII(Dcbpy)2(CN)2], M = Na, K) exhibited 4.2 times higher solubility (1.22 M, 33 Ah/L) and a 50% increase in potential compared with the widely used ferrocyanide. The symmetry-breaking, iron complex catholyte-based AORFBs were demonstrated at a concentration near the solubility limit (1.02 M Na4[FeII(Dcbpy)2(CN)2]) with a 1:1 catholyte:anolyte electron ratio. The AORFBs achieved a cell voltage of 1.2 V and a demonstrated energy density of 12.5 Wh/L. This symmetry-breaking design paves the way for development of metal complexes for high-energy-density AORFBs.

Li, Xiang↗
DOE OSTI2023

Online data-driven changepoint detection for high-dimensional dynamical systems

In this study, the detection of anomalies or transitions in complex dynamical systems is of critical importance to various applications. In this study, we propose the use of machine learning to detect changepoints for high-dimensional dynamical systems. Here, changepoints indicate instances in time when the underlying dynamical system has a fundamentally different characteristic—which may be due to a change in the model parameters or due to intermittent phenomena arising from the same model. We propose two complementary approaches to achieve this, with the first devised using arguments from probabilistic unsupervised learning and the latter devised using supervised deep learning. To accelerate the deployment of transition detection algorithms in high-dimensional dynamical systems, we introduce dimensionality reduction techniques. Our experiments demonstrate that transitions can be detected efficiently, in real-time, for the two-dimensional forced Kolmogorov flow and the Rössler dynamical system, which are characterized by anomalous regimes in phase space where dynamics are perturbed off the attractor at potentially uneven intervals. Finally, we also demonstrate how variations in the frequency of detected changepoints may be utilized to detect a significant modification to the underlying model parameters by utilizing the Lorenz-63 dynamical system.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Numerical Simulations of Orographic Convection across Multiple Gray Zones

Idealized simulations are used to determine the sensitivity of moist orographic convection to horizontal grid spacing Δ h . In simulated mechanically (MECH) and thermally (THERM) forced convection over an isolated ridge, Δ h is varied systematically over both the deep-convection (Δ h ~ 10 –1 km) and turbulence (Δ h ~ 1 km–100 m) gray zones. To aid physical interpretation, a new parcel-based bulk entrainment/detrainment diagnosis for horizontally heterogeneous flows is developed. Within the deep-convection gray zone, the Δ h sensitivity is dominated by differences in parameterized versus explicit convection; the former initiates convection too far upstream of the ridge (MECH) and too early in the diurnal heating cycle (THERM). These errors stem in part from a large underprediction of parameterized entrainment and detrainment. Within the turbulence gray zone, sensitivities to Δh arise from the representation of both subcloud- and cloud-layer turbulence. As Δ h is decreased, MECH exhibits stronger cloud-layer entrainment to enhance the convective mass flux M co , while THERM exhibits stronger detrainment to suppress Mco and delay convection initiation. The latter is reinforced by increased subcloud turbulence at smaller Δ h , which leads to drying and diffusion of the central updraft responsible for initiating moist convection. Numerical convergence to a robust solution occurs only in THERM, which develops a fully turbulent flow with a resolved inertial subrange (for Δ h ≤ 250 m). In MECH, by contrast, turbulent transition occurs within the orographic cloud, the details of which depend on both physical location and Δ h .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Superconducting metamaterials - the first step toward a microwave quantum bus

Coherent manipulation of quantum states is at the core of quantum information science (QIS). Many state-of-the-art quantum systems rely on microwave fields for quantum operations. As such, the microwave electromagnetic fields serve as the ideal "quantum bus" to integrate different types of QIS systems into a hybrid quantum system. Superconducting metamaterials are artificial materials consisting of arrays of superconducting resonant microstructures with sizes much smaller than the microwave wavelengths of interest. Superconducting metamaterials are a strong candidate medium for the microwave quantum bus, because the effective impedance, field distributions, and frequency response can all be controlled by engineering the microstructures, electrical bias, and magnetic flux while maintaining extremely low loss. In this project, we investigate the fundamental unit of a superconducting metamaterial - a resonator with physical dimensions much smaller than the microwave wavelengths - using NbTiN as the working superconductor, whose high operating temperatures and magnetic fields are desirable attributes for compatibility with a wide variety of quantum systems. We first studied the properties of sputtered NbTiN thin films by correlating the film thickness with the normal state resistivity, superconducting transition temperature, and resonances of transmission line resonators made from these films. We developed a process flow and designed a coplanar waveguide platform for studying small resonators. The platform significantly shortens the turnaround times of the resonator fabrication and testing cycles. Several resonators with different designs were fabricated and tested at 4 Kelvin. Resonances were observed in some resonator testers. Potential paths for improvements and future directions are discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Digital Twin Model for Advanced Manufacture of a Rotating Detonation Engine Injector

A digital twin material model (DTMM) of an additive manufacturing (AM) process was created to advance the state of the art in rotating detonation engine (RDE) injector design. Current RDE injectors are designed with large pressure drops, enabling a stable and repeatable combustion process. However, this comes at the cost of system efficiency. For the technology to transition to commercial fossil-based power generation, it is important to develop injectors with reduced flow losses. Low-loss injectors are difficult to design and manufacture with conventional manufacturing techniques. AM enables new design options, but the AM manufacturing process must be thoroughly understood to result in a robust design. A DTMM provides the necessary insight by defining the cause-effect relationships between process parameters, microstructure features, and properties. Therefore, a DTMM to support the design and manufacturing process was developed and applied to the design of a new additively manufactured low-loss injector. The injector combustion behavior was characterized through hot-fire tests, and mechanical performance was compared to the DTMM predictions. The two project goals were the successful development of the DTMM and the demonstration of an improved RDE injector design. The RDE injector design and DTMM developments occurred on parallel but dependent paths. The injector was designed to reduce pressure drop by increasing the cross-sectional flow area ratio between the injector air passages and the combustor annulus. This resulted in less structural material, raising the concern that thin members would be susceptible to high-cycle fatigue (HCF) under the periodic loading inherent to an RDE. It was most important for the DTMM to predict behavior in these features; therefore, the injector design concept guided the material thicknesses used in fatigue tests. The DTMM development started by manufacturing a series of coupons over the range of possible AM process variations. A design-of-experiment approach was used to select which process variable combinations gave the most efficient coverage relevant to the injector design space. The microstructure in each of these coupons was characterized, and then computational methods were used to create a numerical model of the correlation between process variables and microstructure. Next, a set of HCF samples were tested to calibrate existing models that map microstructure to HCF performance. Together, these two links formed the DTMM that calculates HCF behavior from AM process variables. Two injector prototypes were additively manufactured. The first injector design strategy aggressively pursued low-loss performance by substantially increasing the oxidizer flow area. The combination of manufacturing lead times and the fatigue testing schedule meant that the DTMM was not available when building this first prototype. Therefore, its process parameters were chosen based on a manual review of the available coupon data. This prototype was built successfully and evaluated in 58 combustion tests. Sustained detonation was achieved with remarkably reduced pressure loss, and some tests even displayed pressure loss characteristics similar to conventional gas turbine combustors. This achieved the project goal of improving RDE injector design. The second injector was manufactured according to the optimized parameters predicted by the DTMM. The flow area modifications of this injector were less aggressive than the first injector since demonstrating low pressure loss was not an objective of the second hot-fire test series. Rather, the test objective was to cause high cycle fatigue failure in the part due to periodic loading from the rotating detonation wave. The observed number of cycles to failure was to be compared to the number predicted by the DTMM and thereby assess the utility of the DTMM in component design. However, the required level of vibration was not obtained during combustion. Therefore, high cycle fatigue was not experienced in the hot-fire tests of the second injector. Fatigue data was obtained by further testing the second injector in a conventional HCF test apparatus. The injector demonstrated HCF strength above the DTMM prediction. In fact, it did not fail and testing was only discontinued due to reaching the end of the period of performance. This points to some success in the project’s primary goal of successfully developing and applying the DTMM to a component design. Implementing the DTMM recommendations for optimal processing parameters led to a part with acceptable properties. The DTMM was also shown to be an efficient correlator of data and to provide insight into the relationship between process settings, microstructure, and property performance. However, the failure of the DTMM prediction to match the experimental result of the injector fatigue test also points to the need to include significantly more data in the model development. In this project, coupons made with identical processing parameters exhibited drastically different properties from each other and from the injector part, which clearly influences the accuracy of a model that predicts performance based on parameters. Uncertainties in the build process must be quantified to develop more robust models. A denser and broader matrix of coupon process and geometry variations, several repeated builds of every point, more in-situ build process measurements, and direct observation of tensile and HCF sample microstructure (as opposed to separate microstructure specimens) are recommendations to improve future AM modeling efforts.

20 FOSSIL-FUELED POWER PLANTS↗