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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 433 records · Page 24

Large-eddy simulation study on cycle-to-cycle variation of knocking combustion in a spark-ignition engine

The cycle-to-cycle variation in the knock intensity is commonly encountered under abnormal combustion conditions. The severity of these abnormal combustion events can vary significantly, and the efficiency of engines at high loads is limited in practice by heavy knocking phenomena. Since, a thorough analysis of such recurrent but non-cyclic phenomena via experiments alone becomes highly cumbersome, in the present work, a multi-cycle large-eddy simulation study was performed to quantitatively predict cyclic variability in the combustion process and cyclic knock intensity variability in a direct injection spark-ignition engine. To account for the turbulence-chemistry interaction effects on flame propagation, the G-equation combustion model was used. Detailed chemistry was solved outside the flame front with a toluene primary reference fuel skeletal kinetic mechanism. For both the mild knock and heavy knock conditions, the numerical results were validated against experimental measurements. Based on the simulation results, a correlation analysis was performed considering combustion phasing, peak cylinder pressure and maximum amplitude of pressure oscillation. Furthermore, a detailed three-dimensional spatial analysis illustrated the evolution of auto-ignition kernel development and propagation of pressure waves during knocking combustion for three typical cycles with different knock intensities. In this process, it was found that an early occurrence of auto-ignition in the end gas was prone to high knock intensity. Although multiple auto-ignition kernels were observed in different cycles, the degree of coupling between chemical heat release and pressure waves varied, thereby leading to different maximum amplitude of pressure oscillation values.

42 ENGINEERING↗

Development and Life Prediction of Erosion Resistant Turbine Low Conductivity Thermal Barrier Coatings

Future rotorcraft propulsion systems are required to operate under highly-loaded conditions and in harsh sand erosion environments, thereby imposing significant material design and durability issues. The incorporation of advanced thermal barrier coatings (TBC) in high pressure turbine systems enables engine designs with higher inlet temperatures, thus improving the engine efficiency, power density and reliability. The impact and erosion resistance of turbine thermal barrier coating systems are crucial to the turbine coating technology application, because a robust turbine blade TBC system is a prerequisite for fully utilizing the potential coating technology benefit in the rotorcraft propulsion. This paper describes the turbine blade TBC development in addressing the coating impact and erosion resistance. Advanced thermal barrier coating systems with improved performance have also been validated in laboratory simulated engine erosion and/or thermal gradient environments. A preliminary life prediction modeling approach to emphasize the turbine blade coating erosion is also presented.

Zhu, Dongming↗

Elucidating the Roles of Local and Nonlocal Rate Enhancement Mechanisms in Plasmonic Catalysis

Plasmonic metal nanoparticles (e.g., Ag, Au, and Cu) constitute a class of materials that interact with light via the excitation of localized surface plasmon resonance (LSPR). Numerous studies have reported substantial enhancements in the rates of chemical reactions on illuminated plasmonic nanoparticle catalysts compared to corresponding systems in the absence of illumination. There are two mechanisms that have been proposed to explain the LSPR-induced chemical reactivity. One mechanism assumes a local plasmon-induced hot charge-carrier-mediated activation of the reactants, while the other assumes an LSPR-induced equilibrium heating of the catalyst, which leads to energy transfer to and chemical reaction of the adsorbed reactants. Here, in this contribution, we developed a setup amenable to accurate in situ catalyst temperature and kinetic reaction rate measurements. We employed this setup to study the LSPR-induced rate enhancement in a case study of the CO oxidation reaction on plasmonic, monometallic Ag nanoparticle catalysts supported on α-Al 2 O 3 . We explored various Ag loadings and clustering levels. Our data show that the equilibrium heating of the catalyst cannot fully explain the illumination-induced plasmonic rate enhancements. This is the case even for high loading and clustering of Ag nanoparticles, where the equilibrium heating significantly increases. Based on the analysis, we propose that local effects, related to the plasmon-induced activation of adsorbates (reactants) via electronic excitation of the reactant or photothermal heating of the reactants that is highly localized to the individual nanoparticles, play a critical role in driving LSPR-induced chemical reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Comparison Made of Operating Characteristics of Spiral Bevel Gears Manufactured Using Different Methods

Spiral bevel gears are important components on all current rotorcraft drive systems. These components are required to operate at high speeds, high loads, and for an extremely large number of load cycles. In this application, spiral bevel gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor. Because of the high expense of manufacturing these gears, methods that can achieve the same level of performance at reduced cost are highly desirable to aerospace gear manufacturers. Gears manufactured for aerospace applications use high-quality materials and are manufactured to tight tolerances. Special manufacturing machine tools and computer numerically controlled coordinate measurement systems have enabled rotorcraft drive system manufacturers to produce extremely high-quality gears during their normal production. Because of low production rates for rotorcraft, these gears are manufactured in small batches, and thus are unable to benefit from the economics of high production numbers as in other industries. In this investigation, two different manufacturing methods, face-milled and face-hobbed, were used to fabricate spiral bevel gears. For face-milled spiral bevel gears, grinding of the contacting surfaces is the final manufacturing step. At least two different specialty machines are needed to generate the teeth for face-milled spiral bevel gears. For face-hobbed gears, hard cutting is the final manufacturing process. The same machine is used to rough cut and finish cut the gears. This study compared the operational behavior of face-milled spiral bevel gears with that of face-hobbed spiral bevel gears. Test hardware was manufactured to fit within NASA Glenn Research Center's Spiral Bevel Test Facility and to aerospace quality standards. Tests were conducted for stress, vibration, and noise. A comparison of the results attained indicated that the face-hobbed gears had a lower alternating stress level with a more even distribution of loading across the teeth, and slightly reduced levels of vibration and noise. Results of this study show that the face-hobbed method is a viable and lower-cost alternative for producing aerospace-quality spiral-bevel gears.

Handschuh, Robert F.↗

Structured for success: conjugated polymer binders with tailored composition and architecture for lithium-ion batteries

Conjugated polymer binders are replacing conventional binders in lithium-ion batteries. Herein, we examine how molecular engineering and hierarchical nanostructuring govern binder functionality and electrochemical performance. Lithium-ion batteries (LIBs) are the leading energy storage technology, yet enhancing their energy density and cycle life remains critical. Significant progress has been made in high-capacity anodes and high-voltage cathodes, but their performance is hindered by electrode degradation, where it is related to the behaviors of binders at the surface and interface. Conventional non-conductive binders like poly(vinylidene difluoride) (PVDF), combined with conductive additives, often fail to maintain electrical pathways under repeated volume changes. Alternatively, conjugated polymer binders have emerged as a superior alternative, simultaneously offering intrinsic conductivity, mechanical flexibility, and strong adhesion through π-conjugated backbones and functional groups. Their tunable molecular structure enables efficient electron/ion transport while mitigating electrode cracking. Additionally, the development of hierarchically ordered nanostructures in conjugated polymer binder can further enhance their electrochemical performance. This review examines the design principles of conjugated polymer binders, focusing on molecular engineering and nanostructural control to optimize their performance in high-loading electrodes, such as silicon-based anodes. By addressing key challenges in binder functionality, these advanced materials pave the way for next-generation high-energy-density LIBs.

Jin, Xiuyu↗

Large-Strain Transparent Magnetoactive Polymer Nanocomposites

A document discusses polymer nano - composite superparamagnetic actuators that were prepared by the addition of organically modified superparamagnetic nanoparticles to the polymer matrix. The nanocomposite films exhibited large deformations under a magnetostatic field with a low loading level of 0.1 wt% in a thermoplastic polyurethane elastomer (TPU) matrix. The maximum actuation deformation of the nanocomposite films increased exponentially with increasing nanoparticle concentration. The cyclic deformation actuation of a high-loading magnetic nanocomposite film was examined in a low magnetic field, and it exhibited excellent reproducibility and controllability. Low-loading TPU nanocomposite films (0.1-2 wt%) were transparent to semitransparent in the visible wavelength range, owing to good dispersion of the magnetic nanoparticles. Magnetoactuation phenomena were also demonstrated in a high-modulus, high-temperature polyimide resin with less mechanical deformation.

Meador, Michael A.↗

Interactions of an Imine Polymer with Nanoporous Silica and Carbon in Hybrid Adsorbents for Carbon Capture

Efficient carbon capture from stationary point sources can be achieved using hybrid adsorbents comprising nanoporous substrates coated with imine polymers. The physical properties of the CO 2 -adsorbing, nanodispersed polymers are altered by their interactions with the substrate, which in turn may impact their capture capacity. We study silica and carbon nanoporous substrates with different pore morphologies that were impregnated with polymer imine with the goal of characterizing the polymer dispersions in the pores. For silica and carbon samples, the mean densities of confined poly(ethylene imine) (PEI) were measured as functions of polymer loading and temperature using small-angle neutron scattering. Strong densification is found for imine polymers imbibed in mesoporous carbon. PEI in nanoporous silica does not experience this strong densification. At high loadings, plugs form, preferably at the pore throats, and can reduce accessible porosity. CO 2 capture measurements show that PEI interactions with the substrate play an important role. In conclusion, PEI in carbon shows the highest capture capacity at low temperatures and the lowest CO 2 adsorption at high temperatures, making it well-suited for temperature swing adsorption applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Co-Free Cathode Materials and Their Novel Architectures

To enable cobalt-free LiNi 0.5 Mn 1.5 O 4 (LNMO) electrode and novel electrolyte formulation for use in next-generation Li-ion batteries (LIB) capable of high energy density, long cycle life and low cost, several methods were developed throughout this project. To enhance the performance of LNMO, Fe-doping on LNMO, laser treatment and atomic layer deposition (ALD) were adopted. Moreover, dry electrode method has successfully helped to fabricate ultra-high loading LNMO with stable performance. The improvement at anode side includes ALD-coating as well as pre-lithiation of graphite anode. In the novel electrolyte development, it was found that all-fluorinated electrolyte with appropriate additives can effectively extend both cycle and calendar life of LNMO full cells at practical loadings. Additional diagnosis of LNMO full cells showed that different types of carbon and porosity of separator play a critical role in the success of LNMO’s high voltage operation. The combined effort throughout the project pushed forward the understanding and commercialization of LNMO at practical level.

25 ENERGY STORAGE↗

The application of elastohydrodynamic lubrication in gear tooth contacts.

It is shown that in the early stages of design, scoring and fatigue failure of gear contact surfaces can be prevented by the following means: improving load capacity with the aid of tip relief, or by improved surface finish; by giving special care to the location and application of the lubricant in high-speed or high-load gear applications; by determining the thickness of the elastohydrodynamic film from an analysis for the worst temperature, speed, and load conditions, and selecting the appropriate lubricant from this analysis; by using an additive in the case of frequent repeated startup and shutdown conditions; by taking the expected temperature, speed, and load in the selection of an extreme pressure additive; and by systematically testing any new transmission or gear box design.

Townsend, D. P.↗

Thermally Insulating Support for Cryogenic Tanks

Passive alternate-load-path support scheme keeps weight low while conserving cryogenic liquid. Method of supporting inner vessel of large Dewar container minimizes heat conductance and weight but ensures high strength and impact resistance. Accommodates thermal expansion and contraction of vessel while introducing minimal stresses in structure. Inner vessel hangs from struts in outer vessel. Thin wall graphite/epoxy tube protected from high loads by close tolerance stops.

Parmley, Richard T.↗

Face-gear drives: Design, analysis, and testing for helicopter transmission applications

The use of face-gears in helicopter transmissions was explored. A light-weight, split-torque transmission design utilizing face-gears is described. Face-gear design and geometry were investigated. Topics included tooth generation, limiting inner and outer radii, tooth contact analysis, contact ratio, gear eccentricity, grinding, and structural stiffness. Design charts were developed to determine minimum and maximum face-gear inner and outer radii. An analytical study showed that the face-gear drive is relatively insensitive to gear misalignment with respect to transmission errors, but the tooth contact is affected by misalignment. A method of localizing the bearing contact to permit operation with misalignment was explored. Two new methods for grinding of the face-gear tooth surfaces were also investigated. The proper choice of shaft stiffness enabled good load sharing in the split-torque transmission design. Face-gear experimental studies were also conducted. These tests demonstrated the feasibility of face-gears in high-speed, high-load applications such as helicopter transmissions.

Litvin, F. L.↗

Ultralow platinum loading for redox-flow battery by electrospinning the electrocatalyst and the ionomer in core-shell fibers

Hydrogen Bromine Redox Flow Batteries (HBRFB) are promising candidates for large scale energy storage, having an excellent balance of system, inexpensive and abundant electrolytes, high power density and near zero kinetic limitations. However, they suffer from corrosion of the hydrogen electrode due to bromine species crossover, which requires a high loading of precious group metal (PGM) electrocatalyst. Herein, a standard catalyst has been used in an electrospun (ES) fiber mat electrode, allowing for a significant (six-fold) reduction in platinum loading from 0.3 mg Pt /cm 2 down to 0.05 mg Pt /cm 2 . At this very low loading, the electrospun electrode attained an impressive specific power of 11.5W/mg Pt , and exhibited excellent durability, with constant power output for 140 charge/discharge cycles. Further, the excellent performance of the electrospun hydrogen electrode is attribute to its unique core-shell nanofiber structure, which improves the stability of the catalyst by preventing bromide species from reaching the catalyst surface.

25 ENERGY STORAGE↗

Sliding Contact Bearings for Service to 700 C

Cylindrical, sliding contact bearings made entirely of a self-lubricating powder metallurgy composite (PM212) or of super alloy shells lined with clad PM212 were tested in an oscillating mode at temperatures from 25 to 700 C. Tests of 100 hr duration or longer were conducted at a bearing unit load of 3.45 Mpa (500 psi). Shorter duration tests at various unit loads up to 24.1 Mpa (3500 psi) were also conducted. In comparison tests, bearings lubricated with PM212 had superior anti-wear characteristics compared to the baseline, unlubricated, super alloy bearings: no galling of PM212-lubricated bearings occurred, while severe surface damage including galling occurred, especially at high loads, during the baseline tests. A heat treatment procedure, which dimensionally stabilizes PM212 and thereby minimizes clearance changes during high temperature bearing operation, is described.

Sliney, Harold E.↗

Structural load control during construction

In the absence of gravitational pull, the major design considerations for large space structures are stiffness for controllability, and transient dynamic loadings (as opposed to the traditional static load associated with earth-based structures). Because of the absence of gravitational loading, space structures can be designed to be significantly lighter than their counterparts on Earth. For example, the Space Shuttle manipulator arm is capable of moving and positioning a 60,000 lb payload, yet weighs less than 1,000 lbs. A recent design for the Space Station which had a total weight of about 500,000 lbs. used a primary loadcarrying keel beam which weighed less than 10,000 lbs. For many large space structures designs it is quite common for the load-carrying structure to have a mass fraction on the order of one or two percent of the total spacecraft mass. This significant weight reduction for large space structures is commonly accompanied by very low natural frequencies. These low frequencies cause an unprecedented level of operational complexity for mission applications which require a high level of positioning and control accuracy. This control problem is currently the subject of considerable research directed towards reducing the flexibility problem. In addition, however, the small mass fraction typically results in structures which are quite unforgiving to inadvertent high loadings. In other words, the structures are 'fragile.' In order to deal with the fragility issue CSC developed a load-limiting concept for space truss structures. This concept is aimed at limiting the levels of load which can occur in a large space structure during the construction process as well as during subsequent operations. Currently, the approach for dealing with large loadings is to make the structure larger. The impact this has on construction is significant. The larger structures are more difficult to package in the launch vehicle, and in fact in some instances the concept must be changed from a deployable truss to an erectable truss to permit packaging. The new load-limiting concept is aimed at permitting the use in large space structures of smaller trusses with a high level of strength robustness, in order to simplify the construction process. To date several analyses conducted on the concept have demonstrated its feasibility, and an experiment is currently being designed to demonstrate its operation.

Mikulas, Martin M., Jr.↗

Quantification of Cyclic Ground Reaction Force Histories During Daily Activity in Humans

Theoretical models and experimental studies of bone remodeling suggest that bone density and structure are influenced by local cyclic skeletal tissue stress and strain histories. Estimation of long-term loading histories in humans is usually achieved by assessment of physical activity level by questionnaires, logbooks, and pedometers, since the majority of lower limb cyclic loading occurs during walking and running. These methods provide some indication of the mechanical loading history, but fail to consider the true magnitude of the lower limb skeletal forces generated by various daily activities. These techniques cannot account for individual gait characteristics, gait speed, and unpredictable high loading events that may influence bone mass significantly. We have developed portable instrumentation to measure and record the vertical component of the ground reaction force (GRFz) during normal daily activity. This equipment allows long-term quantitative monitoring of musculoskeletal loads, which in conjunction with bone mineral density assessments, promises to elucidate the relationship between skeletal stresses and bone remodeling.

Breit, G. A.↗

Complex Flow Separation Pattern on Transonic Fan Airfoils Revealed by Flow Visualization

Modern turbofan engines employ a highly loaded fan stage with transonic or low-supersonic velocities in the blade-tip region. The fan blades are often prone to flutter at off-design conditions. Flutter is a highly undesirable and dangerous self-excited mode of blade oscillations that can result in high-cycle fatigue blade failure. The origins of blade flutter are not fully understood yet. The latest view is that the blade oscillations are triggered by high-frequency changes in the extent of the partially separated area on the airfoil suction side. There is a lack of experimental data describing the separated flow characteristics of modern airfoils for transonic fans.

Lepicovsky, Jan↗

Fan Stall Flutter Flow Mechanism Studied

Modern turbofan engines employ a highly loaded fan stage with transonic or low-supersonic velocities in the blade-tip region. The fan blades are often prone to flutter at off-design conditions. Flutter is a highly undesirable and dangerous self-excited mode of blade oscillations that can result in high-cycle fatigue blade failure. The origins of blade flutter are not fully understood yet. Experimental data that can be used to clarify the origins of blade flutter in modern transonic fan designs are very limited. The Transonic Flutter Cascade Facility at the NASA Glenn Research Center was developed to experimentally study the details of flow mechanisms associated with fan flutter. The cascade airfoils are instrumented to measure high-frequency unsteady flow variations in addition to the steady flow data normally recorded in cascade tests. The test program measures the variation in surface pressure in response to the oscillation of one or more of the cascade airfoils. However, during the initial phases of the program when all airfoils were in fixed positions, conditions were found where significant time variations in the pressures near the airfoil leading edges could be observed.

Lepicovsky, Jan↗

Scintillation Hydro-Gel for Isotopic Neutron (SHINE): Eco-Friendly Quantum Dot Neutron Detectors

The development of new neutron detectors to replace helium-3 (3He) detectors is imperative due to a worldwide shortage of 3He following the draw down in nuclear weapons production since the end of the Cold War. The United States Department of Homeland Security would like to deploy monitors for the detection of neutron emissions from shipping containers housing illicit nuclear material; however, this effort has been put on hold until new replacements for 3He detectors can be developed. Scintillation Hydro-Gel for isotopic Neutron Emitters (SHINE) is a unique, first of its kind, 6Li-loaded quantum dot gel scintillator developed at INL. By incorporating 6Li with quantum dots in a gel matrix, SHINE displays the best properties of liquid and solid scintillators without their disadvantages such as continuous filtering to keep liquids free of contaminates, slow throughput of containers, higher base component costs, ‘dead’ voids in solid scintillators, and a high loading of 6Li without compromising on light transparency. Additionally, SHINE is completely eco-friendly, a breakthrough in high-efficiency detection systems. SHINE is a unique combination of 6LiCl, a highly water-soluble compound, and InP/ZnS core/shell quantum dots, which are poured into a gel-form using cross-linking polymers. In this presentation, SHINE has been successfully tested for neutron detection and shows promise as both a replacement for current 3He neutron detectors as well as potential use in handheld, compact neutron detection units and antineutrino detection.

36 MATERIALS SCIENCE↗