Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “thermal engineering”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Heavy Duty Natural Gas Single Cylinder Research Engine Installation, Commissioning, and Baseline Testing

Natural Gas (NG) Internal Combustion Engines (ICE) are a promising alternative to diesel engines for on-road heavy-duty applications to reduce greenhouse gas and harmful pollutant emissions. NG engines have not been widely adopted due to the lower thermal efficiency compared with diesel engine counterparts. To develop the base knowledge required to reach the desired efficiency, a Single Cylinder Engine (SCE) is the most effective platform to acquire reliable and repeatable data. A SCE test cell was developed using a Cummins 15-liter six-cylinder heavy-duty engine block modified to fire one cylinder (2.5-liter displacement). A Woodward Large Engine Control Module (LECM) is integrated to permit implementation of real-time advanced combustion control. Intake and exhaust characteristics, fuel composition, and exhaust gas recirculated substitution rate (EGR) are fully adjustable. A high-speed data acquisition system acquires in-cylinder, intake, and exhaust pressure for combustion analysis. The baseline testing shows reliable and consistent results for engine thermal efficiency, indicated mean effective pressure (IMEP), and coefficient of variance of the IMEP over a wide range of operating conditions while achieving effective control of all engine control and operation variables. This test cell will be used to conduct a research program to develop new and innovative control algorithms and CFD optimized combustion chamber designs, allowing ultra-high efficiency and low emissions for NG ICE heavy-duty on-road applications.

03 NATURAL GAS↗
NASA NTRS1993

Advanced transportation system studies. Alternate propulsion subsystem concepts: Propulsion database

The Advanced Transportation System Studies alternate propulsion subsystem concepts propulsion database interim report is presented. The objective of the database development task is to produce a propulsion database which is easy to use and modify while also being comprehensive in the level of detail available. The database is to be available on the Macintosh computer system. The task is to extend across all three years of the contract. Consequently, a significant fraction of the effort in this first year of the task was devoted to the development of the database structure to ensure a robust base for the following years' efforts. Nonetheless, significant point design propulsion system descriptions and parametric models were also produced. Each of the two propulsion databases, parametric propulsion database and propulsion system database, are described. The descriptions include a user's guide to each code, write-ups for models used, and sample output. The parametric database has models for LOX/H2 and LOX/RP liquid engines, solid rocket boosters using three different propellants, a hybrid rocket booster, and a NERVA derived nuclear thermal rocket engine.

Levack, Daniel↗
NASA NTRS2005

Safe Affordable Fission Engine-(SAFE-) 100a Heat Exchanger Thermal and Structural Analysis

A potential fission power system for in-space missions is a heat pipe-cooled reactor coupled to a Brayton cycle. In this system, a heat exchanger (HX) transfers the heat of the reactor core to the Brayton gas. The Safe Affordable Fission Engine- (SAFE-) 100a is a test program designed to thermally and hydraulically simulate a 95 Btu/s prototypic heat pipe-cooled reactor using electrical resistance heaters on the ground. This Technical Memorandum documents the thermal and structural assessment of the HX used in the SAFE-100a program.

Steeve, B. E.↗
DOE OSTI2022

Temperature-Following Thermal Barrier Coatings for High Efficiency Engines (Final Report)

HRL Laboratories and General Motors (GM), pursued this effort to increase the efficiency of internal combustion engines (ICEs) by developing and implementing temperature-following thermal barrier coatings (TBCs) to decrease heat loss from the combustion chamber. HRL developed microsphere TBCs based on hollow high-temperature alloy spheres with average diameter of 50 μm and wall thickness ~1 μm (microspheres) that achieve unprecedented low thermal conductivity and heat capacity (10X lower than the state of the art) while offering exceptional environmental and mechanical resistance.> In current ICEs, approximately 29% of the fuel’s energy is lost to the cooling system and about 22% goes into moving the car. By limiting heat losses from the combustion chamber with insulating coatings, fuel energy can be redirected into additional piston work and into the exhaust stream. The additional energy that goes into the exhaust stream can be turned into useful work through the use of an exhaust energy recovery device, such as turbocompounding and/or through driving a turbocharger to increase the power density of the engine allowing downsizing. Insulating coatings for piston crowns have been pursued in the past, but previous materials—typically ceramics—exhibited low thermal conductivity but retained high heat capacity. Such materials reduce heat losses but stabilize at a high surface temperature. The high surface temperature heats the incoming gases, which lowers volumetric efficiency and increases propensity for knock, resulting in degraded engine performance. This program developed an innovative new material that combines low thermal conductivity with low heat capacity. These unique properties allow it to follow rapid changes in gas temperature during each combustion cycle. A metallic microsphere TBC has been demonstrated that exhibits increased surface temperature during the combustion period, resulting in reduced heat transfer losses, while still returning to a low surface temperature during the gas exchange period. A 10X lower thermal conductivity and heat capacity than state-of-the-art thermal barrier coatings has been demonstrated. These unprecedented thermal properties are achieved through the coating architecture, which consists of closed pores on the microscale and exhibits a total porosity of 90% to 95%. By selecting a high-temperature nickel alloy as the coating material, the ductility and strength of metals can be harnessed to achieve much better durability and damage tolerance than brittle ceramic coatings can achieve.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Integrated Molten Salt Reactor Modeling Capabilities in NEAMS Thermal Hydraulics Tools

The DOE Nuclear Energy Advanced Modeling and Simulation (NEAMS) program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad range of advanced reactor concepts. The research and development approach under the thermal fluids technical area synergistically combines three length and time scales in a hierarchical multi-scale approach. To enable multi-scale thermal fluids capability using these codes, a key joint effort has been underway to develop an integrated system- and engineering-scale thermal fluids analysis capability, through integration of SAM and Pronghorn codes, both based on the MOOSE framework.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1992

Thermal stratification potential in rocket engine coolant channels

The potential for rocket engine coolant channel flow stratification was computationally studied. A conjugate, 3-D, conduction/advection analysis code (SINDA/FLUINT) was used. Core fluid temperatures were predicted to vary by over 360 K across the coolant channel, at the throat section, indicating that the conventional assumption of a fully mixed fluid may be extremely inaccurate. Because of the thermal stratification of the fluid, the walls exposed to the rocket engine exhaust gases will be hotter than an assumption of full mixing would imply. In this analysis, wall temperatures were 160 K hotter in the turbulent mixing case than in the full mixing case. The discrepancy between the full mixing and turbulent mixing analyses increased with increasing heat transfer. Both analysis methods predicted identical channel resistances at the coolant inlet, but in the stratified analysis the thermal resistance was negligible. The implications are significant. Neglect of thermal stratification could lead to underpredictions in nozzle wall temperatures. Even worse, testing at subscale conditions may be inadequate for modeling conditions that would exist in a full scale engine.

Kacynski, Kenneth J.↗
NASA NTRS1992

Design of a high-temperature experiment for evaluating advanced structural materials

This report describes the design of an experiment for evaluating monolithic and composite material specimens in a high-temperature environment and subject to big thermal gradients. The material specimens will be exposed to aerothermal loads that correspond to thermally similar engine operating conditions. Materials evaluated in this study were monolithic nickel alloys and silicon carbide. In addition, composites such as tungsten/copper were evaluated. A facility to provide the test environment has been assembled in the Engine Research Building at the Lewis Research Center. The test section of the facility will permit both regular and Schlieren photography, thermal imaging, and laser Doppler anemometry. The test environment will be products of hydrogen-air combustion at temperatures from about 1200 F to as high as 4000 F. The test chamber pressure will vary up to 60 psia, and the free-stream flow velocity can reach Mach 0.9. The data collected will be used to validate thermal and stress analysis models of the specimen. This process of modeling, testing, and validation is expected to yield enhancements to existing analysis tools and techniques.

Mockler, Theodore T.↗
NASA NTRS2003

Powder-Derived High-Conductivity Coatings for Copper Alloys

Makers of high-thermal-flux engines prefer copper alloys as combustion chamber liners, owing to a need to maximize heat dissipation. Since engine environments are strongly oxidizing in nature and copper alloys generally have inadequate resistance to oxidation, the liners need coatings for thermal and environmental protection; however, coatings must be chosen with great care in order to avoid significant impairment of thermal conductivity. Powder-derived chromia- and alumina- forming alloys are being studied under NASA's programs for advanced reusable launch vehicles to succeed the space shuttle fleet. NiCrAlY and Cu-Cr compositions optimized for high thermal conductivity have been tested for static and cyclic oxidation, and for susceptibility to blanching - a mode of degradation arising from oxidation-reduction cycling. The results indicate that the decision to coat the liners or not, and which coating/composition to use, depends strongly on the specific oxidative degradation mode that prevails under service conditions.

Thomas-Ogbuji, Linus U.↗
NASA NTRS1971

Factors affecting the thermal shock behavior of yttria stabilized hafnia based graphite and tungsten composites.

Hafnia-based composites containing either graphite or tungsten were investigated as rocket nozzle throat inserts in solid propellant rocket engines. The thermal shock resistance of these materials is considered in terms of macroscopic thermal conductivity, thermal expansion, modulus of elasticity, and compressive fracture stress. The effect of degree of hafnia stabilization, density, and graphite or tungsten content upon these parameters is discussed. The variation of the ratio of elastic modulus to compressive fracture stress with density and its effect upon thermal shock resistance of these materials are discussed in detail.

Lineback, L. D.↗
NASA NTRS1977

Atmospheric cloud physics thermal systems analysis

Engineering analyses performed on the Atmospheric Cloud Physics (ACPL) Science Simulator expansion chamber and associated thermal control/conditioning system are reported. Analyses were made to develop a verified thermal model and to perform parametric thermal investigations to evaluate systems performance characteristics. Thermal network representations of solid components and the complete fluid conditioning system were solved simultaneously using the Systems Improved Numerical Differencing Analyzer (SINDA) computer program.

Source record↗
NASA NTRS1995

Thermal barrier coating life modeling in aircraft gas turbine engines

Analytical models for predicting ceramic thermal barrier coating (TBC) spalling life in aircraft gas turbine engines are presented. Electron beam-physical vapor deposited (EB-PVD) and plasma sprayed TBC systems are discussed. An overview of the following TBC spalling mechanisms is presented: metal oxidation at the ceramic-metal interface, ceramic-metal interface stress singularities at edges and corners, ceramic-metal interface stresses caused by radius of curvature and interface roughness, material properties and mechanical behavior, temperature gradients, component design features and object impact damage. TBC spalling life analytical models are proposed based on observations of TBC spalling and plausible failure theories. TBC spalling was assumed to occur when the imposed stresses exceed the material strength (at or near the ceramic-metal interface). TBC failure knowledge gaps caused by lack of experimental evidence and analytical understanding are noted. The analytical models are considered initial engineering approaches that capture observed TBC failure trends.

Nissley, David M.↗
DOE OSTI2019

Engineering Precisely Controlled Negative and Zero Thermal Expansion Behaviors in Metal-Organic Frameworks

Positive thermal expansion can cause significant stress or even catastrophic device failure in applications where materials are placed in confined environments. At material interfaces such as coatings, thermal expansion effects can also lead to cracking and peeling behavior. The ability to impart controlled thermal expansion properties in an array of designs via additive manufacturing technologies would mitigate such problems and bring significant value to various materials science and engineering challenges. Negative thermal expansion materials are of interest for composite material applications whereby they can compensate for the behavior of a positive thermal expansion matrix. This Truman Fellowship LDRD research project presents complimentary experimental and molecular modeling results towards the fundamental understanding and development of metal-organic framework (MOF) materials with controlled thermal expansion properties. Design strategies for imparting precisely tailored negative, zero, and positive thermal expansion regimes in MOFs are studied and the implications of these design strategies for the use of MOFs as an emergent negative thermal expansion material class are examined. Challenges towards exploiting this nanoscale behavior at length scales relevant to composite material systems are introduced. ACKNOWLEDGEMENTS I will be forever grateful to the Truman Fellowship Selection Committee for providing me with the opportunity to pursue this research project. The unique opportunity to carry out this exciting scientific research with all of the resources and support that Sandia has to offer has been a truly rewarding experience. I would like to especially thank Yolanda Moreno for her endless assistance throughout my time as a Truman Fellow. It is hard to imagine a more supportive and stimulating scientific environment to carry out this research. I would also like to thank all of my colleagues and the individuals that have collaborated with me throughout this Fellowship, both internal and external to Sandia. Many of you appear as co-authors on the publications resulting from this LDRD, including especially fruitful collaborations with researchers at the Georgia Institute of Technology and the University of Amsterdam. I cannot express enough my gratitude for the significant role that you all played in shaping my educational experience and the success during my time at Sandia as a Truman Fellow.

36 MATERIALS SCIENCE↗
NASA NTRS1997

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗
NASA NTRS2016

Post-Flight Assessment of Avcoat Thermal Protection System for the Exploration Flight Test-1

On December 5, 2014 NASA conducted the first flight test of its next generation human-class Orion spacecraft. The flight was called the Exploration Flight Test -1 (EFT-1) which lasted for 4 hours and culminated into a re-entry trajectory at 9 km/s. This flight test of the 5-meter Orion Crew Module demonstrated various sub-systems including the Avcoat ablative thermal protection system (TPS) on the heat shield. The Avcoat TPS had been developed from the Apollo-era recipe with a few key modifications. The engineering for thermal sizing was supported by modeling, analysis, and ground tests in arc jet facilities. This paper will describe a postlfight analysis plan and present results from post-recovery inspections, data analysis from embedded sensors, TPS sample extraction and characterization in the laboratory. After the recovery of the vehicle, a full photographic survey and surface scans of the TPS were performed. The recovered vehicle showed physical evidence of flow disturbances, varying degrees of surface roughness, and excessive recession downstream of compression pads. The TPS recession was measured at more than 200 locations of interest on the Avcoat surface. The heat shield was then processed for sample extraction prior to TPS removal using the 7-Axis Milling machine at Marshall Space Flight Center. Around 182 rectangular TPS samples were extracted for subsequent analysis and investigation. The final paper will also present results of sample analysis. The planned investigation includes sidewall imaging, followed by image analysis to characterize TPS response by quantifying different layers in the char and pyrolysis zones. A full postmortem of the instrumentation and sensor ports will also be performed to confirm no adverse effects due to the sensors themselves. A subset of the samples will undergo structural testing and perform detailed characterization of any cracks and integrity of gore seams. Finally, the material will be characterized with layer-by-layer density measurements and SEM investigations to evaluate material morphology at microstructural level including identification of elements and compounds.

Aerothermodynamics↗
DOE OSTI2022

Inelastic phonon transport across atomically sharp metal/semiconductor interfaces

Understanding thermal transport across metal/semiconductor interfaces is crucial for the heat dissipation of electronics. The dominant heat carriers in non-metals, phonons, are thought to transport elastically across most interfaces, except for a few extreme cases where the two materials that formed the interface are highly dissimilar with a large difference in Debye temperature. In this work, we show that even for two materials with similar Debye temperatures (Al/Si, Al/GaN), a substantial portion of phonons will transport inelastically across their interfaces at high temperatures, significantly enhancing interface thermal conductance. Moreover, we find that interface sharpness strongly affects phonon transport process. For atomically sharp interfaces, phonons are allowed to transport inelastically and interface thermal conductance linearly increases at high temperatures. With a diffuse interface, inelastic phonon transport diminishes. Our results provide new insights on phonon transport across interfaces and open up opportunities for engineering interface thermal conductance specifically for materials of relevance to microelectronics.

42 ENGINEERING↗
NASA NTRS1977

Improved high pressure turbine shroud

A new high pressure turbine shroud material has been developed from the consolidation of prealloyed powders of Ni, Cr, Al and Y. The new material, a filler for cast turbine shroud body segments, is called Genaseal. The development followed the identification of oxidation resistance as the primary cause of prior shroud deterioration, since conversion to oxides reduces erosion resistance and increases spalling under thermal cycled engine conditions. The NICrAlY composition was selected in preference to NIAL and FeCRALY alloys, and was formulated to a prescribed density range that offers suitable erosion resistance, thermal conductivity and elastic modulus for improved behavior as a shroud.

Bessen, I. I.↗