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At least 415 records · Page 23

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DOE OSTI2024

Thermal images collected during large-scale 3D printing with Ingersoll MasterPrint

This data set contains images produced to test the performance of anomaly and fault detection methods in the context of additive manufacturing. Two print jobs were executed using the Ingersoll MasterPrint with the Model 30 Strangpresse extruder. The material used was Techmer compounded polylactic acid (PLA) with wood flour as a filler (80/20 PLA/WF by weight). The first print job consists of the 3D printing of a hexagonal cylinder with a two-bead wall. This print was sliced at a gantry velocity of 3000 millimeter per minute, and an extruder screw speed of 68.14 rotations per minute. This are considered the normal operating conditions. A second hexagonal cylinder was printed using a reduced extruder screw speed, 15% lower than under normal operating conditions. The images were collected with a Teledyne FLIR Lepton 3.5 infra-red camera, a small form factor radiometric long-wave infrared camera with a spectral range of 8 µm to 14 µm. Sensor resolution was 160x120 pixels, with a pixel size of 12 µm, a temperature range of -10 - 450°C, and an accuracy of +/- 10°C in its low gain configuration. Images in this data set were collected with cameras oriented at the printer nozzle. The nozzle camera setup consisted of two cameras located 12.5cm from the nozzle center. These were mounted directly to the print head, so that the camera positions relative to the print direction would remain constant as it rotated around its C-axis to follow the print path. One camera was placed ahead of the nozzle to capture the previous layer immediately before being covered by the new layer of material, while the second camera was placed behind the nozzle and captured the freshly extruded bead. Images are collecting during each phase of the print: (a) idle (i.e., no material deposited), (b) extrusion (i.e., to prime the extruder), and (c) printing (deposition of material to manufacture the hexagonal cylinder).

36 MATERIALS SCIENCE↗

DOE OSTI2023

Large Eddy Simulation of Externally Induced Ingress about an Axial Seal by Stator Vanes

Turbine inlet temperatures in advanced gas turbines could be as high as 2000 °C. To prevent ingress of this hot gas into the wheelspace between the stator and rotor disks, whose metals can only handle temperatures up to 850 °C, rim seals and sealing flows are used. This study examines the abilities of large eddy simulation (LES) based on the WALE subgrid model and Reynolds-averaged Navier–Stokes (RANS) based on the SST model in predicting ingress in a rotor–stator configuration with vanes but no blades, a configuration with experimental data for validation. Results were obtained for an operating condition, where the ratio of the external Reynolds number to the rotational Reynolds number is 0.538. At this operating condition, both LES and RANS were found to correctly predict the coefficient of pressure, C p , located downstream of the vanes and upstream of the seal, but only LES was able to correctly predict the sealing effectiveness. This shows C p by itself is inadequate in quantifying externally induced ingress. RANS was unable to predict the sealing effectiveness because it significantly under predicted the pressure drop in the hot gas path along the axial direction, especially about the seal region. This affected the pressure difference across the seal in the radial direction, which ultimately drives ingress.

42 ENGINEERING↗

NASA NTRS1989

Improved Si:As BIBIB (Back-Illuminated Blocked-Impurity-Band) hybrid arrays

Results of a program to increase the short wavelength (less than 10 microns) detective quantum efficiency, eta/beta, of Si:As Impurity Band Conduction arrays are presented. The arrays are epitaxially grown Back-Illuminated Blocked (BIB) Impurity-Band (BIBIB) 10x50 detectors bonded to switched-FET multiplexers. It is shown that the 4.7 microns detective quantum efficiency increases proportionately with the thickness of the infrared active layer. A BIB array with a thick active layer, designed for low dark current, exhibits eta/beta = 7 to 9 percent at 4.7 microns for applied bias voltages between 3 and 5 V. The product of quantum efficiency and photoelectric gain, etaG, increases from 0.3 to 2.5 as the voltage increases from 3 to 5 V. Over this voltage range, the dark current increases from 8 to 120 e(-)s(-1) at a device temperature of 4.2 K and is under 70 e(-)s(-1) for all voltages at 2 K. Because of device gain, the effective dark current (equivalent photon rate) is less than 3 e(-)s(-1) under all operating conditions. The effective read noise (equivalent photon noise) is found to be less than 12 electrons under all operating conditions and for integration times between 0.05 and 100 seconds.

Herter, T.↗

NASA NTRS2015

Initial Thrust Measurements of Marshall's Ion-ioN Thruster

Electronegative ion thrusters are a variation of traditional gridded ion thruster technology differentiated by the production and acceleration of both positive and negative ions. Benefits of electronegative ion thrusters include the elimination of lifetime-limiting cathodes from the thruster architecture and the ability to generate appreciable thrust from both charge species. While much progress has been made in the development of electronegative ion thruster technology, direct thrust measurements are required to unambiguously demonstrate the efficacy of the concept and support continued development. In the present work, direct thrust measurements of the thrust produced by the MINT (Marshall's Ion-ioN Thruster) are performed using an inverted-pendulum thrust stand in the High-Power Electric Propulsion Laboratory's Vacuum Test Facility-1 at the Georgia Institute of Technology with operating pressures ranging from 4.8 x 10(exp -5) and 5.7 x 10(exp -5) torr. Thrust is recorded while operating with a propellant volumetric mixture ratio of 5:1 argon to nitrogen with total volumetric flow rates of 6, 12, and 24 sccm (0.17, 0.34, and 0.68 mg/s). Plasma is generated using a helical antenna at 13.56 MHz and radio frequency (RF) power levels of 150 and 350 W. The acceleration grid assembly is operated using both sinusoidal and square waveform biases of +/-350 V at frequencies of 4, 10, 25, 125, and 225 kHz. Thrust is recorded for two separate thruster configurations: with and without the magnetic filter. No thrust is discernable during thruster operation without the magnetic filter for any volumetric flow rate, RF forward Power level, or acceleration grid biasing scheme. For the full thruster configuration, with the magnetic filter installed, a brief burst of thrust of approximately 3.75 mN +/- 3 mN of error is observed at the start of grid operation for a volumetric flow rate of 24 sccm at 350 W RF power using a sinusoidal waveform grid bias at 125 kHz and +/- 350 V. Similar bursts in thrust are observed using a square waveform grid bias at 10 kHz and +/- 350 V for volumetric flow rates of 6, 10, and 12 sccm at 150, 350, and 350 W respectively. The only operating condition that exhibits repeated thrust spikes throughout thruster operation is the 24 sccm condition with a 5:1 mixture ratio at 150 W RF power using the 10 kHz square waveform acceleration grid bias. Thrust spikes for this condition measure 3 mN with an error of +/- 2.5 mN. There are no operating conditions tested that show continuous thrust production.

Caruso, Natalie R. S.↗

NASA NTRS2008

Progress of Ongoing NASA Lithium-Ion Cell Verification Testing for Aerospace Applications

A Lithium-ion Verification and Validation Program with the purpose to assess the capabilities of current aerospace lithium-ion (Li-ion) battery cells to perform in a low-earth-orbit (LEO) regime was initiated in 2002. This program involves extensive characterization and LEO life testing at ten different combinations of depth-of-discharge, temperature, and end-of-charge voltage. The test conditions selected for the life tests are defined as part of a statistically designed test matrix developed to determine the effects of operating conditions on performance and life of Li-ion cells. Results will be used to model and predict cell performance and degradation as a function of test operating conditions. Testing is being performed at the Naval Surface Warfare Center/Crane Division in Crane, Indiana. Testing was initiated in September 2004 with 40 Ah cells from Saft and 30 Ah cells from Lithion. The test program has been expanded with the addition of modules composed of 18650 cells from ABSL Power Solutions in April 2006 and the addition of 50 Ah cells from Mine Safety Appliances Co. (MSA) in June 2006. Preliminary results showing the average voltage and average available discharge capacity for the Saft and Lithion packs at the test conditions versus cycles are presented.

McKissock, Barbara I.↗

NASA NTRS2002

Overview of High-Fidelity Modeling Activities in the Numerical Propulsion System Simulations (NPSS) Project

A high-fidelity simulation of a commercial turbofan engine has been created as part of the Numerical Propulsion System Simulation Project. The high-fidelity computer simulation utilizes computer models that were developed at NASA Glenn Research Center in cooperation with turbofan engine manufacturers. The average-passage (APNASA) Navier-Stokes based viscous flow computer code is used to simulate the 3D flow in the compressors and turbines of the advanced commercial turbofan engine. The 3D National Combustion Code (NCC) is used to simulate the flow and chemistry in the advanced aircraft combustor. The APNASA turbomachinery code and the NCC combustor code exchange boundary conditions at the interface planes at the combustor inlet and exit. This computer simulation technique can evaluate engine performance at steady operating conditions. The 3D flow models provide detailed knowledge of the airflow within the fan and compressor, the high and low pressure turbines, and the flow and chemistry within the combustor. The models simulate the performance of the engine at operating conditions that include sea level takeoff and the altitude cruise condition.

Veres, Joseph P.↗

DOE OSTI2022

Methane foam performance evaluation in water-wet unconsolidated porous media: A systematic experimental investigation at elevated pressure and temperature conditions

In the petroleum industry, enhanced oil recovery (EOR) techniques employ foam extensively to establish conformance control in heterogeneous and fractured reservoirs in order to increase the sweep efficiency. In such applications, foam performance evaluation under complex subsurface conditions is pivotal for the effective and optimized deployment of foam treatment. However, there is a scarcity of hydrocarbon gas foam generation and evaluation studies that examine the relationships between foam performance and the critical foam parameters at high-pressure and high-temperature conditions. Here, this study aims at methodically investigating the effects of several foam parameters on methane foam performance in water-wet proppant packs under harsh operating conditions. This is in relation to the technical needs of hydrocarbon foam injection into hydraulically-induced, propped fractures in unconventional oil reservoirs. To this end, a state-of-the-art experimental foam generation apparatus was designed, fabricated, and commissioned. We performed a large number of foam flow experiments on proppant packs using methane gas and different foaming agents at 3500 psi and 115°C. Anionic and amphoteric surfactants were employed to probe the effect of their ionic nature on foam performance. Foam performance sensitivities to various foam generation parameters and operating conditions, such as surfactant concentration, gas fraction, total injection rate, operating pressure, salinity, and proppant pack length were investigated. To this end, steady-state pressure drops across the proppant packs during foam generation and foam's apparent viscosity were measured to quantify the foam performance of surfactants. The results were then analyzed to determine optimum values of the foam parameters and the interplay between these parameters are discussed here. The systematic results achieved from this work are in agreement with the trends available in the literature and provide new insights into complexities of in situ foam generation in water-wet, unconsolidated porous media at extreme reservoir conditions.

03 NATURAL GAS↗

NASA NTRS2014

Simulation Tool for Dielectric Barrier Discharge Plasma Actuators

Traditional approaches for active flow separation control using dielectric barrier discharge (DBD) plasma actuators are limited to relatively low speed flows and atmospheric conditions. This results in low feasibility of the DBDs for aerospace applications. For active flow control at turbine blades, fixed wings, and rotary wings and on hypersonic vehicles, DBD plasma actuators must perform at a wide range of conditions, including rarified flows and combustion mixtures. An efficient, comprehensive, physically based DBD simulation tool can optimize DBD plasma actuators for different operation conditions. Researchers are developing a DBD plasma actuator simulation tool for a wide range of ambient gas pressures. The tool will treat DBD using either kinetic, fluid, or hybrid models, depending on the DBD operational condition.

Likhanskii, Alexander↗

NASA NTRS1991

A row-by-row off-design performance calculation method for turbines

The turbine component of a gas turbine engine is frequently subjected to extreme operation conditions associated with significant changes in mass flow, turbine inlet temperature, pressure and rotational speed. These off-design operation conditions significantly affect the flow deflection within the turbine stage, which consists of individual stator and rotor rows. As a result, the stage parameters representing the velocity diagram will change and affect the efficiency and performance of the stage and, thus, the turbine. A row-by-row calculation method is presented for predicting the performance behavior of turbines under extreme off-design conditions. The method is applied to a multistage turbine for which the off-design performance is calculated and compared with the measurement.

Schobeiri, T.↗

DOE OSTI2020

A microchannel shell-and-tube absorber for ammonia-water absorption

A shell-and-tube absorber with microscale geometric features that yields significant volumetric heat duties is investigated. A vertically-oriented baffled shell-and-tube heat exchanger with a tightly packed tube bundle is designed to serve as the absorber for a 10.5 kW nominal cooling capacity absorption chiller. The heat and mass transfer in this absorber is investigated experimentally at operating conditions spanning a wide range of working fluid and coupling fluid flow rates and ambient temperatures. An experimental facility is fabricated to closely simulate the operating conditions in an absorption refrigeration system. Absorption heat duties in the range of 5-15 kW are measured. In addition to operating the absorber in the baseline co-current flow configuration with premixed inlet, fluid ports are provided to enable operation in counter-current flow, where the dilute solution enters from the top and vapor enters from the bottom. The performance of these two flow configurations is compared. A preliminary heat and mass transfer model is developed to quantify the local temperatures, concentrations, and mass flow rates of the solution and vapor streams along the length of the absorber. The model predictions for total heat duty agree with the experimental results within 10% for almost all the data points, with an AAD of ~3.4%. Finally, the results of this study, along with the modeling framework, can guide further development of highly compact and efficient absorbers absorption systems.

42 ENGINEERING↗

DOE OSTI2022

Data Curation for Machine Learning Applied to Geothermal Power Plant Operational Data for GOOML: Geothermal Operational Optimization with Machine Learning: Preprint

Geothermal Operational Optimization with Machine Learning (GOOML) is a transferable and extensible component-based geothermal asset modeling framework that considers complex steamfield relationships and identifies optimization prospects using a data-driven approach to physics-guided, data-centric machine learning. This framework has been used to develop digital twins that provide steamfield operators with operational environments to analyze and understand historical and forecasted power production, explore new steamfield configuration possibilities, and seek optimal asset management in real world applications. To create, test, and apply the GOOML framework, diverse time-series datasets spanning multiple years were sourced from various geothermal power plant components within several complex real-world geothermal operations. These operations are based in the United States and New Zealand and include a variety of technologies, end-uses and configurations, collectively covering nearly all relevant operating conditions for modern geothermal fields. Datasets were acquired from multiple sources to ensure that machine learning experiments generalized properly to various operating conditions. It was found that the data varied in quality, format, and completeness. To ensure consistency between the various datasets, a standardized data curation process was developed to reliably streamline data preparation. This paper will discuss best practices as learned from the GOOML data curation process which takes the following steps: 1) acquisition of large quantities of data from power plant operators, 2) digestion of data to gain an initial understanding of what is included, 3) data transformation, which includes converting the data into a standardized machine-readable format so that they can be visualized, quality checked, and cleaned, 4) quality assurance and quality control, involving identification of significant data gaps and apparent anomalies through mapping of data features to real world componentry via the GOOML historical model, followed by discussion with modelers and power plant operators to identify additional data needs and to resolve issues, 5) use in machine learning algorithms, and 6) repetition of steps one through five until all data needs are met and data are deemed suitable for producing trustworthy modeling results which may be disseminated, ideally along with the curated dataset. This iterative process is focused on improving the quality of the data rather than tuning machine learning model parameters and supports a shift towards data-centric AI as a means to improving real-world applicability of geothermal machine learning projects.

access↗

NASA NTRS1988

The development of an advanced generic solar dynamic heat receiver thermal model

An advanced generic solar dynamic heat receiver thermal model under development which can analyze both orbital transient and orbital average conditions is discussed. This model can be used to study advanced receiver concepts, evaluate receiver concepts under development, analyze receiver thermal characteristics under various operational conditions, and evaluate solar dynamic system thermal performances in various orbit conditions. The model and the basic considerations that led to its creation are described, and results based on a set of baseline orbit, configuration, and operational conditions are presented to demonstrate the working of the receiver model.

Wu, Y. C.↗

DOE OSTI2024

Instantaneous mesh load factor ( K γ ) measurements in a wind turbine gearbox using fiber-optic strain sensors

The mesh load factor, K γ , describes how loads are shared between planet gears and has become one of the key design challenges in modern wind turbine gearboxes. Planet load sharing directly impacts tooth root stresses, a critical driver of torque density and gearbox reliability. Experimental evaluation of K γ is typically performed from sun gear tooth root strain gauge measurements, which are complex. Furthermore, such measurements can only provide an average value of load sharing. The present study describes an alternative method to evaluate the mesh load factor in wind turbine gearboxes based on fiber-optic strain sensors installed on the outer surface of the fixed ring gear. We present the results of an extensive measurement campaign to evaluate this novel sensing solution installed on the input planetary stage of a 2-MW wind turbine gearbox at the National Renewable Energy Laboratory's Flatirons Campus (Colorado, USA). The number of strain sensors on the ring gear was selected as an integer multiple of the number of planets, which has enabled an instantaneous evaluation of the mesh load factor. The effect of operating conditions on the planet load-sharing behavior of the gearbox has been investigated. The mesh load factor measured for operating conditions close to rated was below 1.05, well below IEC 61400-4 standard requirements.

17 WIND ENERGY↗

DOE OSTI2023

Assessment of an E10 gasoline surrogate: Qualitative and quantitative comparisons of in-cylinder spray morphology

A minimum-component gasoline fuel surrogate that captures both chemical and physical behaviors of a full-distillate fuel is needed for high-fidelity CFD simulations. This study evaluates gasoline spray characteristics in a direct-injection spark-ignition engine under motored operation. Two fuels are compared; PACE-20, which is a 9-component surrogate formulation of RD5-87, is compared with its target fuel RD5-87, which is a full-boiling range research grade E10 gasoline. The spray morphologies of both fuels are recorded for a centrally-located direct-injection 8-hole spray subject to intake air cross-flow during the early part of the intake stroke. High-speed imaging recorded scattered light of the side and axial projections of the liquid spray. Quantitative metrics were developed and employed to facilitate comparison of spray morphologies as well as to identify the transition in spray morphology due to flash boiling. This paper builds on a previous study of RD5-87 where coolant temperature (20°C–100°C), in-cylinder pressure (40–110 kPa), engine speed (650–1950 rpm), and injection pressure (60–180 bar) were systematically changed to span operating conditions with and without flash boiling. Images of the PACE-20 morphology are selected for a sub-set of operating conditions from the previous study where distinctive morphology changes occurred. Visual inspection of the images and quantitative metrics demonstrate that the PACE-20 spray morphology is equivalent to that of the RD5-87 in most cases. The exception was for changes in the ambient-gas pressure where the flash-boiling transition occurred at ∼5 kPa higher in-cylinder pressure for PACE-20. Three empirical metrics, Merging Index, Asymmetry, and Flash Index are proposed here and they were found to be useful both as quantitative comparisons of the fuel morphologies, and for identifying the transition in spray morphology due to flash boiling.

Kim, Namho↗

NASA NTRS1992

Wind tunnel performance results of swirl recovery vanes as tested with an advanced high speed propeller

Tests of swirl recovery vanes designed for use in conjunction with advanced high speed propellers were carried out at the NASA Lewis Research Center. The eight bladed 62.23 cm vanes were tested with a 62.23 cm SR = 7A high speed propeller in the NASA Lewis 2.44 x 1.83 m Supersonic Wind Tunnel for a Mach number range of 0.60 to 0.80. At the design operating condition for cruise of Mach 0.80 at an advance ratio of 3.26, the vane contribution to the total efficiency approached 2 percent. At lower off-design Mach numbers, the vane efficiency is even higher, approaching 4.5 percent for the Mach 0.60 condition. Use of the swirl recovery vanes essentially shifts the peak of the high speed propeller efficiency to a higher operating speed. This allows a greater degree of freedom in the selection of rpm over a wider operating range. Another unique result of the swirl recovery vane configuration is their essentially constant torque split between the propeller and the swirl vanes over a wide range of operating conditions for the design vane angle.

Gazzaniga, John A.↗

NASA NTRS1993

Bar-Chart-Monitor System For Wind Tunnels

Real-time monitor system provides bar-chart displays of significant operating parameters developed for National Full-Scale Aerodynamic Complex at Ames Research Center. Designed to gather and process sensory data on operating conditions of wind tunnels and models, and displays data for test engineers and technicians concerned with safety and validation of operating conditions. Bar-chart video monitor displays data in as many as 50 channels at maximum update rate of 2 Hz in format facilitating quick interpretation.

Jung, Oscar↗

NASA NTRS2001

Testing of Face-milled Spiral Bevel Gears at High-speed and Load

Spiral bevel gears are an important drive system components of rotorcraft (helicopters) currently in use. In this application the spiral bevel gears are required to transmit very high torque at high rotational speed. Available experimental data on the operational characteristics for thermal and structural behavior is relatively small in comparison to that found for parallel axis gears. An ongoing test program has been in place at NASA Glenn Research Center over the last ten years to investigate their operational behavior at operating conditions found in aerospace applications. This paper will summarize the results of the tests conducted on face-milled spiral bevel gears. The data from the pinion member (temperature and stress) were taken at conditions from slow-roll to 14400 rpm and up to 537 kW (720 hp). The results have shown that operating temperature is affected by the location of the lubricating jet with respect to the point it is injected and the operating conditions that are imposed. Also the stress measured from slow-roll to very high rotational speed, at various torque levels, indicated little dynamic affect over the rotational speeds tested.

Handschuh, Robert F.↗

NASA NTRS2001

Testing of Face-milled Spiral Bevel Gears at High-speed and Load

Handschuh, Robert F.↗