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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Comparison of Non-Combusting Spray Fields in a Model Combustor using Shadowgraphy

Droplet sizes were measured using shadowgraphy in the spray issuing from the center element of the baseline configuration of the NASA 7-element lean direct injector (LDI) array. Each LDI element consisted of a 60 degree clockwise axial air swirler, converging-diverging venturi, and a pressure-swirl atomizer positioned with its tip at the venturi throat. The non-combusting measurements were conducted using water spray in a 3-inch diameter research combustor operating at pressure of 5 bar and air inlet temperature of 700 K. At these inlet conditions, three air flow rates were used, producing reference velocities of 7.6, 15.2, and 22.9 m/s. Only the center nozzle was used. At each reference velocity, water flow rates were adjusted to simulate a common equivalence. Data were collected at a frame rate of 15 Hz over a range of positions near the LDI dump plane, and downstream, along the combustor centerline. Velocity measurements were achieved by use of a dual head Nd:YAG laser and frame transfer PIV camera. Droplet size and velocity, mass and number density, and volume fraction are compared at these inlet conditions to determine the effect of nozzle pressure drop on the measured properties.

lean direct injection↗
NASA NTRSDate not supplied

Comparison of Non-Combusting Spray Fields in a Model Combustor using Shadowgraphy

Droplet sizes were measured using shadowgraphy in the spray issuing from the center element of the baseline configuration of the NASA 7-element lean direct injector (LDI) array. Each LDI element consisted of a 60 degree clockwise axial air swirler, converging-diverging venturi, and a pressure-swirl atomizer positioned with its tip at the venturi throat. The non-combusting measurements were conducted using water spray in a 3-inch diameter research combustor operating at pressure of 5 bar and air inlet temperature of 700 K. At these inlet conditions, three air flow rates were used, producing reference velocities of 7.6, 15.2, and 22.9 m/s. Only the center nozzle was used. At each reference velocity, water flow rates were adjusted to simulate a common equivalence. Data were collected at a frame rate of 15 Hz over a range of positions near the LDI dump plane, and downstream, along the combustor centerline. Velocity measurements were achieved by use of a dual head Nd:YAG laser and frame transfer PIV camera. Droplet size and velocity, mass and number density, and volume fraction are compared at these inlet conditions to determine the effect of nozzle pressure drop on the measured properties.

lean direct injection↗
DOE OSTI2023

Automated segmentation of porous thermal spray material CT scans with predictive uncertainty estimation

Abstract Thermal sprayed metal coatings are used in many industrial applications, and characterizing the structure and performance of these materials is vital to understanding their behavior in the field. X-ray computed tomography (CT) enables volumetric, nondestructive imaging of these materials, but precise segmentation of this grayscale image data into discrete material phases is necessary to calculate quantities of interest related to material structure. In this work, we present a methodology to automate the CT segmentation process as well as quantify uncertainty in segmentations via deep learning. Neural networks (NNs) have been shown to excel at segmentation tasks; however, memory constraints, class imbalance, and lack of sufficient training data often prohibit their deployment in high resolution volumetric domains. Our 3D convolutional NN implementation mitigates these challenges and accurately segments full resolution CT scans of thermal sprayed materials with maps of uncertainty that conservatively bound the predicted geometry. These bounds are propagated through calculations of material properties such as porosity that may provide an understanding of anticipated behavior in the field.

Martinez, Carianne↗
DOE OSTI2024

Effects of Plume Targeted Cooling on Residual Stress in Controlled Atmosphere Plasma Sprayed Coatings

Thermal spray processes can benefit from cooling to maintain substrate temper, reduce processing times, and manage thermally induced residual stresses. “Plume quenching” is a plume-targeted cooling technique which has been shown to reduce substrate temperatures by redirection of hot plume gases using a lateral argon curtain injected into the plume, while limiting interaction with the substrate or affecting coating properties. Here, this study explores the use of this technique for residual stress management by reducing the thermally driven component in nickel and tantalum coatings on titanium and aluminum substrates. The in-situ residual stress profiles were measured for all substrate and coating pairings during spraying and cooling, and the deposition and thermal stresses recorded. For substrate and coating pairings where the predominant component of residual stress was thermal (driven by a large difference in coefficient of thermal expansion, Δα, between coating and substrate), plume quenching reduced both the thermal stress and the final stress state of the coating. This was seen primarily in tantalum on aluminum coatings where the Δα was -17 × 10 -6 /°C, and thermal stress was reduced by 7.5% and 22.4% for the plume quenching rates of 50 and 100 slpm, respectively.

42 ENGINEERING↗
DOE OSTI2022

Irradiation-induced amorphization of UO 2 films prepared by spraying-assisted combustion synthesis

Spraying-assisted combustion synthesis with uranyl nitrate – acetylacetone – 2-methoxyethanol solutions was used to prepare UO 2 films on an aluminum alloy substrate. The tuning of the spraying parameters and annealing temperatures allowed the preparation of UO 2 films with thicknesses varying from 10–300 nm and 5–10 nm UO 2 grain size. High-resolution electron microscopy and X-ray photoelectron spectroscopy showed that increasing the annealing temperature promotes Mg diffusion from the substrate into the films. The incorporation of Mg reduced the overall crystallinity of the films. The irradiation with Ar 2+ ions (1.7 MeV energy and a fluence of 2 × 10 16 ions/cm 2 ) did not degrade the quality of the films. However, the Mg content significantly influenced the irradiation-induced restructuring of the UO 2 films. Irradiated films with low or no Mg content exhibit high crystallinity, and the UO 2 /Al interfacial layer becomes highly porous. Films with higher Mg content are mostly amorphized after irradiation. The origin of irradiation-induced amorphization was related to the formation of Mg y U 1-y O 2±x solid solutions. Chemically complex, pore-free, and amorphous Mg-Al-O film/substrate interfacial layers enable continuous Mg diffusion during irradiation. As a result, the gradual increase in Mg amounts triggers irradiation-induced precipitation of a crystalline MgO-rich phase within the amorphous films.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2021

Durability of plasma sprayed Thermal Barrier Coatings with controlled properties part Ⅱ: Effects of geometrical curvature

The present investigation elucidates the effects of substrate curvature on the durability of Air Plasma Sprayed (APS) Thermal Barrier Coatings (TBCs). Traditionally, planar disk specimens are utilized in Furnace Cycle Testing (FCT). In most cases, delamination is initiated at the disk's free edge and then propagates along the TBC-bond coat interface. However, in turbine components (e.g., blades/vanes), they lack significant free edges and the coatings are deposited on non-flat surfaces of varying radii of curvature. These geometrical discrepancies imply significant differences in the stress states as compared to planar disk specimens. Therefore, the part geometry inevitably affects the TBC failure mechanisms in the turbine system, and consequently influences TBC durability. Nevertheless, these effects have not been fully explored in the past, despite the anecdotal knowledge which suggests the leading edge of turbine blades to be one of the most common failure/spallation locations. Here in this study, representative TBC systems were deposited onto superalloy disks with flat substrate and rods with curved substrate. The experimental results from FCT suggest TBC durability on rods is significantly lower than when sprayed on disks. Furthermore, the durability of TBCs on rods appears to increase with higher porosity, which is contradictory to reported trends for TBCs on disks. In addition, the effects of various bond coats are not consistent with those observed in disks. To clarify the underlying effects of curved geometries, detailed stress analyses were performed. They revealed a state of thermal stresses which is unique to curved geometries. It was found that TBC on rods experience tensile radial stresses as well as tensile hoop stresses during the cooling. These stresses result in a complex interplay in failure processes in rods, which explains the different observed trends in the durability from those obtained with disks.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enhancing cold spray coatings: Microstructural dynamics and performance attributes of Inconel 625 with chromium carbide incorporation for hydropower applications

The incorporation of chromium carbide (CrC) particles into the cold spray (CS) process is known to mitigate nozzle clogging, although at the expense of deposition efficiency. This study explores the intricate microstructural changes induced by varying amounts of CrC powder (12.5 % and 6 %) in conjunction with Inconel-625 (Inc-625) powder. The deposition was carried out onto A27 cast steel under different CS parameters. Microstructural characterization, including detailed electron microscopy studies, reveals a complex yet structurally stable coating. Noteworthy features include grain fragmentation and a cellular structure enriched with Nb and Mo, with minimal plastic deformation of CrC in the matrix. The cold-sprayed coatings exhibit a significant (~4 times) increase in microhardness compared to the A27 substrate. Mechanical and cavitation erosion properties were systematically investigated. Coatings subjected to higher particle energy conditions with a gas pressure of 600 psi and gas temperature of 650 °C, demonstrated superior resistance to cavitation erosion. This resistance is attributed to a combination of factors, including microstructural characteristics and porosity. Altogether, the study provides valuable insights into the structural dynamics and performance of CS coatings enriched with CrC particles.

A27 cast steel↗
DOE OSTI2021

Comparison of the Mechanical Properties of a Conjugated Polymer Deposited Using Spin Coating, Interfacial Spreading, Solution Shearing, and Spray Coating

The mechanical properties of π-conjugated (semiconducting) polymers are a key determinant of the stability and manufacturability of devices envisioned for applications in energy and healthcare. These properties—including modulus, extensibility, toughness, and strength—are influenced by the morphology of the solid film, which depends on the method of processing. To date, the majority of work done on the mechanical properties of semiconducting polymers has been performed on films deposited by spin coating, a process not amenable to the manufacturing of large-area films. Here, we compare the mechanical properties of thin films of regioregular poly(3-heptylthiophene) (P3HpT) produced by three scalable deposition processes—interfacial spreading, solution shearing, and spray coating—and spin coating (as a reference). Our results lead to four principal conclusions. (1) Spray-coated films have poor mechanical robustness due to defects and inhomogeneous thickness. (2) Sheared films show the highest modulus, strength, and toughness, likely resulting from a decrease in free volume. (3) Interfacially spread films show a lower modulus but greater fracture strain than spin-coated films. (4) The trends observed in the tensile behavior of films cast using different deposition processes held true for both P3HpT and poly(3-butylthiophene) (P3BT), an analogue with a higher glass transition temperature. Grazing incidence X-ray diffraction and ultraviolet–visible spectroscopy reveal many notable differences in the solid structures of P3HpT films generated by all four processes. Herein, while these morphological differences provide possible explanations for differences in the electronic properties (hole mobility), we find that the mechanical properties of the film are dominated by the free volume and surface topography. In field-effect transistors, spread films had mobilities more than 1 magnitude greater than any other films, likely due to a relatively high proportion of edge-on texturing and long coherence length in the crystalline domains. Overall, spread films offer the best combination of deformability and charge-transport properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

THz Radar Observations of Hydrometeors in a Spray Chamber

Abstract A THz radar, with its wide bandwidth, is capable of high‐resolution imaging down to the centimeter scale. In this study, a THz radar is applied to detect hydrometeors generated in a spray chamber. The observed backscattering signals show fluctuations at centimeter scales, indicating various hydrometeor distribution patterns along the radar beam. A co‐located High‐Speed Imaging (HSI) sensor is used to measure the Drop Size Distributions (DSD) in the spray chamber. The radar sampling beam is well aligned with the HSI probes, allowing an objective comparison between the remote sensing and in situ observations. In this study, the observed radar power is compared with the power estimated from the HSI measurements. Results show great consistency, with power difference smaller than 0.5 dB. This study demonstrates the feasibility and great potential of using a THz radar for ultra‐high‐resolution observations of clouds in a laboratory facility, and in the real atmosphere.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Initial study on thermal stability of cold spray tantalum coating irradiated with deuterium for fusion applications

Abstract Removal of neutral hydrogen atoms in the plasma edge reduces the number of charge exchange events and thus, the net energy losses in the plasma, significantly improving performance of fusion devices. Effective control of the residual pressure of hydrogen isotopes (HIs) in the plasma edge may be achieved by utilizing a hydrogen absorbing first wall interface capable of withstanding the harsh fusion environment. In this study, we have investigated tantalum (Ta) coating deposited by cold spray technology on 316L stainless steel substrate as a potential plasma-facing material surface. High fluence low energy deuterium plasma irradiation experiments and subsequent thermal annealing cycles associated with thermal desorption spectrometry (TDS) demonstrated superior structural stability of the Ta coating. TDS experiments revealed the outgassing of deuterium (as measure of its retention) for cold spray Ta coatings to be three times higher than bulk Ta and two orders of magnitude greater than bulk polycrystalline W. X-ray photoelectron spectroscopy revealed evolution of oxidation states upon deuterium irradiation and a partial recovery of the metallic signature of Ta after the thermal treatment at 1100 K.

Physics↗
DOE OSTI2022

Beam Spray Thresholds in ICF-Relevant Plasmas

Beam spray measurements suggest thresholds that are a factor of ≈2 to 15× less than expected based on the filamentation figure of merit often quoted in the literature. In this moderate-intensity regime, the relevant mechanism is forward stimulated Brillouin scattering (FSBS). Both weak ion acoustic wave damping and thermal enhancement of ion acoustic waves contribute to the low thresholds. FSBS imparts a redshift to the transmitted beam. Here, regarding the specific possibility of beam spray occurring outside the laser entrance holes of an indirectly driven hohlraum, this shift may be the most concerning feature owing to the high sensitivity of crossed-beam energy transfer to the interacting beam wavelengths in the subsequent overlap region.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods

Air plasma sprayed (APS) flash coatings on high velocity oxygen fuel (HVOF) bond coatings are well known to extend the lifetime of thermal barrier coatings (TBCs). Recent work compared flash coatings of NiCoCrAlY and NiCoCrAlYHfSi applied to both rods and disk substrates of alloy 247. For rod specimens, 100 h cycles were used at 1100 °C in wet air. Both flash coatings significantly improved the lifetime compared to HVOF-only and vacuum plasma spray (VPS)-only MCrAlY bond coatings with no statistical difference between the two flash coatings. For disk specimens tested in 1 h cycles at 1100 °C in wet air, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. The flash coatings formed a mixed oxide-metal zone that appeared to inhibit crack formation and therefore extend lifetime. In addition to the flash coating increasing the bond coating roughness, the underlying HVOF layer acted as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Here, the lower Y+Hf content in the Y-only flash coating appeared to minimize oxidation in the flash layer, thereby increasing the benefit compared to a NiCoCrAlYHfSi flash coating.

42 ENGINEERING↗
DOE OSTI2020

Verification of diesel spray ignition phenomenon in dual-fuel diesel-piloted premixed natural gas engine

Dual-fuel (DF) engines, in which premixed natural gas and air in an open-type combustion chamber is ignited by diesel-fuel pilot sprays, have been more popular for marine use than pre-chamber spark ignition (PCSI) engines because of their superior durability. However, control of ignition and combustion in DF engines is more difficult than in PCSI engines. In this context, here we focus on the ignition stability of n-heptane pilot-fuel jets injected into a compressed premixed charge of natural gas and air at low-load conditions. To aid understanding of the experimental data, chemical-kinetics simulations were carried out in a simplified engine-environment that provided insight into the chemical effects of methane (CH4) on pilot-fuel ignition. The simulations reveal that CH4 has an effect on both stages of n-heptane autoignition: the small, first-stage, cool-flame-type, low-temperature ignition (LTI) and the larger, second-stage, high-temperature ignition (HTI). As the ratio of pilot-fuel to CH4 entrained into the spray decreases, the initial oxidization of CH4 consumes the OH radicals produced by pilot-fuel decomposition during LTI, thereby inhibiting its progression to HTI. Using imaging diagnostics, the spatial and temporal progression of LTI and HTI in DF combustion are measured in a heavy-duty optical engine, and the imaging data are analyzed to understand the cause of severe fluctuations in ignition timing and combustion completeness at low-load conditions. Images of cool-flame and hydroxyl radical (OH*) chemiluminescence serve as indicators of LTI and HTI, respectively. The cycle-to-cycle and spatial variation in ignition extracted from the imaging data are used as key metrics of comparison. The imaging data indicate that the local concentration of the pilot-fuel and the richness of the surrounding natural-gas air mixture are important for LTI and HTI, but in different ways. In particular, higher injection pressures and shorter injection durations increase the mixing rate, leading to lower concentrations of pilot-fuel more quickly, which can inhibit HTI even as LTI remains relatively robust. Decreasing the injection pressure from 80 MPa to 40 MPa and increasing the injection duration from 500 µs to 760 µs maintained constant pilot-fuel mass, while promoting robust transition from LTI to HTI by effectively slowing the mixing rate. This allows enough residence time for the OH radicals, produced by the two-stage ignition chemistry of the pilot-fuel, to accelerate the transition from LTI to HTI before being consumed by CH4 oxidation. Thus from a practical perspective, for a premixed natural gas fuel–air equivalence-ratio, it is possible to improve the “stability” of the combustion process by solely manipulating the pilot-fuel injection parameters while maintaining constant mass of injected pilot-fuel. This allows for tailoring mixing trajectories to offset changes in fuel ignition chemistry, so as to promote a robust transition from LTI to HTI by changing the balance between the local concentration of the pilot-fuel and richness of the premixed natural gas and air. This could prove to be a valuable tool for combustion design to improve fuel efficiency or reduce noise or perhaps even reduce heat-transfer losses by locating early combustion away from in-cylinder walls.

42 ENGINEERING↗
DOE OSTI2021

The effect of transient needle lift on the internal flow and near-nozzle spray characteristics for modern GDI systems investigated by high-speed X-ray imaging

The development of the injector nozzle is a dynamic area in regard of several technical aspects. At first, the internal flow influences the near-field spray characteristics via various phenomena such as cavitation and turbulence. However, these phenomena are not fully understood due to their extremely fast, complex and multiscale nature. Furthermore, it governs the spray targeting inside the combustion chamber. High-speed X-ray imaging of GDI injector nozzles is performed in this study. The experimental results presented are related to the internal flow and primary breakup of discharged liquid jets. The injectors used are equipped with nozzles made of aluminum which have been specially developed for these investigations to enhance optical accessibility. The visualization of the needle motion, in-nozzle flow and the primary breakup region provides several exciting observations. First, the needle lift tracking exhibits short overshooting right before the steady-state of the injection phase. Additionally, this event leads to a short-term, however, significant change in the associated performance of the breakup. This phenomenon is found to be a consequence of the transient behavior of the in-nozzle flow. It is shown that under some circumstances hydraulic flip may occur during this overshooting period. The primary jet breakup region is visualized and evaluated by means of image processing. Thus, the transient behavior of liquid jet expansion is quantified in the vicinity of the nozzle. It is observed that the liquid jet direction deviates from the hole axis already at the nozzle outlet, which is caused by internal flow characteristics.

42 ENGINEERING↗
DOE OSTI2024

Determining tolerance requirements for spray-duct alignment in ducted fuel injection

Several ducted fuel injection (DFI) studies have highlighted the importance of accuracy in aligning the duct axis with that of its corresponding spray for optimal effectiveness, as misalignment adversely impacts the method’s performance. The need for accurate alignment could lead to added manufacturing complexity via tighter tolerances. This study systematically explores cases of horizontal, vertical, and rotational misalignment, analyzing their respective effects on DFI performance. Vertical and horizontal misalignments at the duct inlet plane were varied at magnitudes of 6.25%, 12.5%, and 25.0% of the duct diameter, corresponding to 0.125, 0.25, and 0.5 mm, respectively. Rotational misalignments were set at 1°, 2°, and 4°, corresponding to 3.65%, 7.30%, and 14.6%, respectively, of the duct diameter at its inlet plane. The investigation yields spray-duct alignment tolerance limits and highlights the influence of misalignment direction on emissions due to the interactions with swirl and squish inside the combustion chamber. The results indicate that the tolerance limits for the alignment are within 4° and 0.5 mm relative to the geometrically aligned position. If the misalignment exceeds 4°of rotation or 0.5 mm in the horizontal direction, the beneficial effects on soot reduction using this method are no longer observed. The findings contribute to an understanding that can be used to optimize DFI for cleaner and more efficient combustion in compression-ignition engines.

Şener, Ramazan↗
DOE OSTI2021

Evaluation of liquid-phase thermometry in impinging jet sprays using synchrotron x-ray scattering

Liquid thermometry during primary and secondary breakup of liquid sprays is challenging due to the presence of highly dynamic, optically complex flow features. This work evaluates the use of x-ray scattering from a focused, monochromatic beam of the Advanced Photon Source at Argonne National Laboratory for the measurement of liquid temperatures within the mixing zone of an impinging jet spray. The measured scattering profiles are converted to temperature through a previously developed two-component partial least squares (PLS) regression model. Transmitive mixing during jet merging is inferred through spatial mapping of temperatures within the impingement region. In this work, the technique exhibits uncertainties of ±2K in temperature and 2% in capturing the correct scattering profile, showing its potential utility for probing liquid temperature distributions in multiphase flows.

42 ENGINEERING↗
DOE OSTI2020

Automated Segmentation of Porous Thermal Spray Material CT Scans with Geometric Uncertainty Estimation

Thermal sprayed metal coatings are used in many industrial applications, and characterizing the structure and performance of these materials is vital to understanding their behavior in the field. X-ray Computed Tomography (CT) machines enable volumetric, nondestructive imaging of these materials, but precise segmentation of this grayscale image data into discrete material phases is necessary to calculate quantities of interest related to material structure. In this work, we present a methodology to automate the CT segmentation process as well as quantify uncertainty in segmentations via deep learning. Neural networks (NNs) are shown to accurately segment full resolution CT scans of thermal sprayed materials and provide maps of uncertainty that conservatively bound the predicted geometry. These bounds are propagated through calculations of material properties such as porosity that may provide an understanding of anticipated behavior in the field.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microstructural Changes to Thermally Sprayed Materials Subjected to Dynamic Compression

Dynamic compression of materials can induce a variety of microstructural changes. As thermally-sprayed materials have highly complex microstructures, the expected pressure at which changes occur cannot be predicted a priori. In addition, typical in-situ measurements such as velocimetry are unable to adequately diagnose microstructural changes such as failure or pore collapse. Quasi-isentropic compression experiments with sample recovery were conducted to examine microstructural changes in thermally sprayed tantalum and tantalum-niobium blends up to 8 GPa pressure. Spall fracture was observed in all tests, and post-shot pore volume decreased relative to the initial state. The blended material exhibited larger spall planes with fracture occurring at interphase boundaries. An estimate of the pressure at which pore collapse is complete was determined to be ~26 GPa for pure tantalum and ~19 GPa for the tantalumniobium blend under these loading conditions.

36 MATERIALS SCIENCE↗