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DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗

DOE OSTI2021

INTEGRATE - Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements

The INTEGRATE (Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements) project is developing a new inverse-design capability for the aerodynamic design of wind turbine rotors using invertible neural networks. This AI-based design technology can capture complex non-linear aerodynamic effects while being 100 times faster than design approaches based on computational fluid dynamics. This project enables innovation in wind turbine design by accelerating time to market through higher-accuracy early design iterations to reduce the levelized cost of energy. INVERTIBLE NEURAL NETWORKS Researchers are leveraging a specialized invertible neural network (INN) architecture along with the novel dimension-reduction methods and airfoil/blade shape representations developed by collaborators at the National Institute of Standards and Technology (NIST) learns complex relationships between airfoil or blade shapes and their associated aerodynamic and structural properties. This INN architecture will accelerate designs by providing a cost-effective alternative to current industrial aerodynamic design processes, including: - Blade element momentum (BEM) theory models: limited effectiveness for design of offshore rotors with large, flexible blades where nonlinear aerodynamic effects dominate - Direct design using computational fluid dynamics (CFD): cost-prohibitive - Inverse-design models based on deep neural networks (DNNs): attractive alternative to CFD for 2D design problems, but quickly overwhelmed by the increased number of design variables in 3D problems AUTOMATED COMPUTATIONAL FLUID DYNAMICS FOR TRAINING DATA GENERATION - MERCURY FRAMEWORK The INN is trained on data obtained using the University of Marylands (UMD) Mercury Framework, which has with robust automated mesh generation capabilities and advanced turbulence and transition models validated for wind energy applications. Mercury is a multi-mesh paradigm, heterogeneous CPU-GPU framework. The framework incorporates three flow solvers at UMD, 1) OverTURNS, a structured solver on CPUs, 2) HAMSTR, a line based unstructured solver on CPUs, and 3) GARFIELD, a structured solver on GPUs. The framework is based on Python, that is often used to wrap C or Fortran codes for interoperability with other solvers. Communication between multiple solvers is accomplished with a Topology Independent Overset Grid Assembler (TIOGA). NOVEL AIRFOIL SHAPE REPRESENTATIONS USING GRASSMAN SPACES We developed a novel representation of shapes which decouples affine-style deformations from a rich set of data-driven deformations over a submanifold of the Grassmannian. The Grassmannian representation as an analytic generative model, informed by a database of physically relevant airfoils, offers (i) a rich set of novel 2D airfoil deformations not previously captured in the data , (ii) improved low-dimensional parameter domain for inferential statistics informing design/manufacturing, and (iii) consistent 3D blade representation and perturbation over a sequence of nominal shapes. TECHNOLOGY TRANSFER DEMONSTRATION - COUPLING WITH NREL WISDEM Researchers have integrated the inverse-design tool for 2D airfoils (INN-Airfoil) into WISDEM (Wind Plant Integrated Systems Design and Engineering Model), a multidisciplinary design and optimization framework for assessing the cost of energy, as part of tech-transfer demonstration. The integration of INN-Airfoil into WISDEM allows for the design of airfoils along with the blades that meet the dynamic design constraints on cost of energy, annual energy production, and the capital costs. Through preliminary studies, researchers have shown that the coupled INN-Airfoil + WISDEM approach reduces the cost of energy by around 1% compared to the conventional design approach. This page will serve as a place to easily access all the publications from this work and the repositories for the software developed and released through this pr...

aerodynamics↗

NASA NTRS1987

Summary of studies to reduce wing-mounted propfan installation drag on an M = 0.8 transport

Powerplant installation losses for an advanced, high-speed, turboprop transport have been investigated in the Ames Research Center Transonic Wind Tunnels as a part of the NASA Advanced Turboprop Program (ATP). Force and pressure tests have been completed at Mach numbers from 0.6 to 0.82 on baseline and modified powered-model configurations to determine the magnitude of the losses and to what extent current design tools could be used to optimize the installed performance of turboprop propulsion systems designed to cruise at M = 0.8. Results of the tests indicate a large reduction in installed drag for the modified configuration. The wing-mounted power plant caused destabilizing pitching moments and a negative shift in the zero-lift pitching moment.

Smith, Ronald C.↗

NASA NTRS1997

Logic Design Pathology and Space Flight Electronics

Logic design errors have been observed in space flight missions and the final stages of ground test. The technologies used by designers and their design/analysis methodologies will be analyzed. This will give insight to the root causes of the failures. These technologies include discrete integrated circuit based systems, systems based on field and mask programmable logic, and the use computer aided engineering (CAE) systems. State-of-the-art (SOTA) design tools and methodologies will be analyzed with respect to high-reliability spacecraft design and potential pitfalls are discussed. Case studies of faults from large expensive programs to "smaller, faster, cheaper" missions will be used to explore the fundamental reasons for logic design problems.

Katz, Richard↗

NASA NTRS2017

Computational Assessment of a 3-Stage Axial Compressor Which Provides Airflow to the NASA 11- by 11-Foot Transonic Wind Tunnel, Including Design Changes for Increased Performance

A 24 foot diameter 3-stage axial compressor powered by variable-speed induction motors provides the airflow in the closed-return 11- by 11-Foot Transonic Wind Tunnel (11-Foot TWT) Facility at NASA Ames Research Center at Moffett Field, California. The facility is part of the Unitary Plan Wind Tunnel, which was completed in 1955. Since then, upgrades made to the 11-Foot TWT such as flow conditioning devices and instrumentation have increased blockage and pressure loss in the tunnel, somewhat reducing the peak Mach number capability of the test section. Due to erosion effects on the existing aluminum alloy rotor blades, fabrication of new steel rotor blades is planned. This presents an opportunity to increase the Mach number capability of the tunnel by redesigning the compressor for increased pressure ratio. Challenging design constraints exist for any proposed design, demanding the use of the existing driveline, rotor disks, stator vanes, and hub and casing flow paths, so as to minimize cost and installation time. The current effort was undertaken to characterize the performance of the existing compressor design using available design tools and computational fluid dynamics (CFD) codes and subsequently recommend a new compressor design to achieve higher pressure ratio, which directly correlates with increased test section Mach number. The constant cross-sectional area of the compressor leads to highly diffusion factors, which presents a challenge in simulating the existing design. The CFD code APNASA was used to simulate the aerodynamic performance of the existing compressor. The simulations were compared to performance predictions from the HT0300 turbomachinery design and analysis code, and to compressor performance data taken during a 1997 facility test. It was found that the CFD simulations were sensitive to endwall leakages associated with stator buttons, and to a lesser degree, under-stator-platform flow recirculation at the hub. When stator button leakages were modeled, pumping capability increased by over 20 of pressure rise at design point due to a large reduction in aerodynamic blockage at the hub. Incorporating the stator button leakages was crucial to matching test data. Under-stator-platform flow recirculation was thought to be large due to a lack of seals. The effect of this recirculation was assessed with APNASA simulations recirculating 0.5, 1, and 2 of inlet flow about stators 1 and 2, modeled as axisymmetric mass flux boundary conditions on the hub before and after the vanes. The injection of flow ahead of the stators tended to re-energize the boundary layer and reduce hub separations, resulting in about 3 increased stall margin per 1 of inlet flow recirculated. In order to assess the value of the flow recirculation, a mixing plane simulation of the compressor which gridded the under-stator cavities was generated using the ADPAC CFD code. This simulation indicated that about 0.65 of the inlet flow is recirculated around each shrouded stator. This collective information was applied during the redesign of the compressor. A potential design was identified using HT0300 which improved overall pressure ratio by removing pre-swirl into rotor 1, replacing existing NASA 65 series rotors with double circular arc sections, and re-staggering rotors and the existing stators. The performance of the new design predicted by APNASA and HT0300 is compared to the existing design.

Turbomachinery↗

NASA NTRSDate not supplied

Application of the CATNLF Design Method to a Transonic Transport Empennage Using CDISC

A novel Crossflow Attenuated Natural Laminar Flow (CATNLF) design method has been developed to achieve laminar flow on aircraft empennage at transonic flight conditions. This approach has been applied to the design of a nonlifting vertical tail using CDISC, a knowledgebased aerodynamic design tool developed at the NASA Langley Research Center. A horizontal tail was also designed using an enhanced CATNLF design approach for low-lift components. CDISC was coupled with USM3D-ME, a Navier-Stokes computational fluid dynamics solver. Stability and transition software was used to determine the laminar extent on the surfaces. Results indicate laminar flow can be sustained at midcruise conditions to about x/c=0.40 on the vertical tail and as much as x/c=0.65 on the horizontal tail lower surface. Transonic longitudinal off-design analysis indicates minimal change in the laminar extent. However, nonzero sideslip angles at transonic conditions can cause premature transition relative to the midcruise condition.

Brent W. Pomeroy↗

NASA NTRS1966

Report on explosive sizing of 70-inch diameter welded aluminum preforms from 5086, 2014 T4 and 2014 T6 material Final report, 5 Dec. 1961 - 30 Mar. 1962

Explosive sizing of 70-inch diameter welded aluminum preforms and tool design of explosive form die

ALUMINUM↗

NASA NTRSDate not supplied

Improving Quantification of Medical Evacuation Risk for Human Spaceflight in the IMPACT Model

Traditionally, mission planners have used a heuristic and qualitative approach to design medical systems based on prior experience however this approach may result in high variability and implicit bias to design and could put missions and crewmembers at risk. The Informing Mission Planning through Analysis of Complex Tradespaces (IMPACT) tool is a probabilistic risk assessment tool designed by NASA to model medical risk in long duration missions outside of low earth orbit (LEO). This tool can quantify risk metrics such as risk of crewmember death, loss of crew task time, and the need for medical evacuation to better inform and augment the more traditional approach to medical system design. The risk metric of Return to Definitive Care (RTDC) represents the likelihood of requiring medical evacuation and has been difficult to quantify in a reliable and standardized manner. Initial development of the RTDC metric was constrained due to the complexity of a medical evacuation decision and the lack of prior spaceflight data and this presentation will discuss the review and improvement process used to increase model accuracy and fidelity.

Prashant Parmar↗

NASA NTRSDate not supplied

GlennICE 2.2 Capabilities and Results

GlennICE (Glenn Icing Computational Environment) is a computational tool designed to calculate ice growth on complex three-dimensional geometries using the input from a user-supplied computational fluid dynamics (CFD) solution for the geometry of interest. The NASA John H. Glenn Research Center at Lewis Field is developing this tool to aid those evaluating, designing and certifying aircraft, engines, and aircraft components for flight in icing conditions. This domestically available software is being developed to enable the introduction of new icing physics into a computational environment in a manner that is open for evaluation and eventual use by industry, academia, and other government organizations. This paper will document the current capabilities for version 2.1 of this software and provide example cases with comparison to available experimental data.

Icing↗

NASA NTRSDate not supplied

GlennICE 2.2 Capabilities and Results

Icing↗

NASA NTRS2024

GlennICE Manual 4.1.0

Icing↗

NASA NTRSDate not supplied

Improvements to GlennICE Collection Efficiency Algorithm

GlennICE (Glenn Icing Computational Environment) is a computational tool designed to calculate ice growth on complex three-dimensional geometries using the input from a user-supplied computational fluid dynamics (CFD) solution for the geometry of interest. The NASA John H. Glenn Research Center at Lewis Field is developing this tool to aid those evaluating, designing and certifying aircraft, engines, and aircraft components for flight in icing conditions. This domestically available software is being developed to enable the introduction of new icing physics into a computational environment in a manner that is open for evaluation and eventual use by industry, academia, and other government organizations. This paper will document recent improvements that reduce the number of trajectories needed to converge on collection efficiency. These improvements are documented using example cases with complex geometries.

Aircraft Icing↗

NASA NTRSDate not supplied

Improvements to GlennICE Collection Efficiency Algorithm

GlennICE (Glenn Icing Computational Environment) is a computational tool designed to calculate ice growth on complex three-dimensional geometries using the input from a user-supplied computational fluid dynamics (CFD) solution for the geometry of interest. The NASA John H. Glenn Research Center at Lewis Field is developing this tool to aid those evaluating, designing and certifying aircraft, engines, and aircraft components for flight in icing conditions. This domestically available software is being developed to enable the introduction of new icing physics into a computational environment in a manner that is open for evaluation and eventual use by industry, academia, and other government organizations. This paper will document recent improvements that reduce the number of trajectories needed to converge on collection efficiency. These improvements are documented using example cases with complex geometries.

Aircraft Icing↗

NASA NTRS1996

Integrated Design Systems -Capturing, Reusing and Optimizing Design Methods in New Millenium

An important goal of New Millenium is to research new methods of performing spacecraft and mission design. We have completed the first phase of our effort on how to make design tools such as analysis programs more available. We are now embarking with Stanford University on discovering methods to allow more project history and knowledge to be automatically captured and reused with Ames Research Center on how to use virtual reality to enhance the visualization of new missions before any hardware exists.

New↗

DOE OSTI2025

Nine Canyon Long-Duration Energy Storage: A Feasibility Study

The Nine Canyon Long Duration Energy Storage (LDES) Feasibility Study explores the technical and economic viability of deploying advanced energy storage technologies at Energy Northwest's (EN) Nine Canyon (9C) Wind Project site in Benton County, Washington. Supported by the Washington State Department of Commerce and the U.S. Department of Energy’s Office of Electricity under its LDES Voucher Program, the study represents a collaborative effort between EN, Pacific Northwest National Laboratory (PNNL), and ARES North America. At the core of this effort is the development of a generalized techno-economic modeling framework and evaluation tool designed to assess the value proposition of LDES projects across a variety of contexts. The modeling tool is technology-agnostic and accommodates user-defined parameters such as rated power, energy duration, round-trip efficiency, capital and operational costs, and dispatch constraints. It also integrates economic inputs, including market prices, energy revenue structures, and financing parameters to evaluate performance through key metrics. The tool provides utilities with a transparent, adaptable platform to support decision-making, investment prioritization, and portfolio planning for various storage technologies. To guide scenario design and interpretation, the study first surveyed the LDES technology landscape, including lithium-ion batteries, flow batteries, non-hydro gravity storage, and thermo-mechanical systems, comparing cost trajectories, technical performance, safety and hazards, materials sourcing and recyclability, and spatial/siting considerations. This literature-grounded review highlights technology trade-offs and reinforces the need to align technology choice with site characteristics, use cases, and project objectives. A companion chapter examines ownership structures (EN ownership, third-party ownership, shared models) and offtake options (energy marketing, capacity/energy PPAs, time-of-use PPAs, block-delivery PPAs, and tolling), where PPAs (power purchase agreements) represent contractual arrangements for buying and selling electricity. The chapter also highlights implications for risk allocation, capital access, operational control, and revenue certainty. The study also evaluates supervisory control and data acquisition (SCADA) and transmission interconnection pathways, options include upgrading the existing SCADA or deploying a dedicated LDES controller, with attention to protection schemes, data telemetry, cybersecurity, and regulatory coordination with BPA. In addition, an ARES-specific geotechnical and hydrology assessment presented in the appendix screens multiple corridors for slope stability, bearing capacity, cut-and-fill magnitude, and stormwater behavior.

25 ENERGY STORAGE↗

NASA NTRS2012

Development of a Robust and Efficient Parallel Solver for Unsteady Turbomachinery Flows

The traditional design and analysis practice for advanced propulsion systems relies heavily on expensive full-scale prototype development and testing. Over the past decade, use of high-fidelity analysis and design tools such as CFD early in the product development cycle has been identified as one way to alleviate testing costs and to develop these devices better, faster and cheaper. In the design of advanced propulsion systems, CFD plays a major role in defining the required performance over the entire flight regime, as well as in testing the sensitivity of the design to the different modes of operation. Increased emphasis is being placed on developing and applying CFD models to simulate the flow field environments and performance of advanced propulsion systems. This necessitates the development of next generation computational tools which can be used effectively and reliably in a design environment. The turbomachinery simulation capability presented here is being developed in a computational tool called Loci-STREAM [1]. It integrates proven numerical methods for generalized grids and state-of-the-art physical models in a novel rule-based programming framework called Loci [2] which allows: (a) seamless integration of multidisciplinary physics in a unified manner, and (b) automatic handling of massively parallel computing. The objective is to be able to routinely simulate problems involving complex geometries requiring large unstructured grids and complex multidisciplinary physics. An immediate application of interest is simulation of unsteady flows in rocket turbopumps, particularly in cryogenic liquid rocket engines. The key components of the overall methodology presented in this paper are the following: (a) high fidelity unsteady simulation capability based on Detached Eddy Simulation (DES) in conjunction with second-order temporal discretization, (b) compliance with Geometric Conservation Law (GCL) in order to maintain conservative property on moving meshes for second-order time-stepping scheme, (c) a novel cloud-of-points interpolation method (based on a fast parallel kd-tree search algorithm) for interfaces between turbomachinery components in relative motion which is demonstrated to be highly scalable, and (d) demonstrated accuracy and parallel scalability on large grids (approx 250 million cells) in full turbomachinery geometries.

West, Jeff↗

NASA NTRS2018

Biocene 2018 - Welcome to the Period of New Life

Biocene is the period of new life. When our descendants look back at this period in time, they will see evidence, in the geologic and electronic record, of anthropic climate change, growing population, and scarcity of resources. But they will also see the rebirth of human ingenuity as we overcame the challenges that faced us through nature-inspired exploration. The Periodic Table of Life (PeTaL) is a proposed tool and open source framework that uses artificial intelligence to aid in the systematic inquiry of biology for its application to human systems. This presentation defines the PeTaL concept and workflow. Biomimicry, biophysics, biomimetics, bionics and numerous other terms refer to the use of biology and biological principles to inform practices in other disciplines. For the most part, the domain of inquiry in these fields have been confined to extant biological models with the proponents of biomimicry often citing the evolutionary success of extant organisms relative to extinct ones. The primary objective of this paper is to expand the domain of inquiry for human processes that seek to model those that are, were or could be found in nature with examples that relate to the field of aerospace and to spur development of tools that can work together to accelerate the use of artificial intelligence in problem solving. Specifically specialized fields such as paleomimesis, anthropomimesis and physioteleology are proposed in conjunction with artificial evolution. Blockchain technology may be vital in allowing open source design tools such as PeTaL to democratize design and yet protect intellectual property. The overarching philosophy outlined here can be thought of as physiomimetics, a holistic and systematic way of learning from natural history. The backbone of PeTaL integrates an unstructured database with an ontological model consisting of function, morphology, environment, state of matter and ecosystem. Tools include text classification, thesaurus, data visualization, and analysis. Applications of PeTaL include guiding human space exploration, understanding human and geological history, and discovering new or extinct life.

Biocene↗

NASA NTRS1983

An application of nonlinear programming to the design of regulators of a linear-quadratic formulation

A design technique is proposed for linear regulators in which a feedback controller of fixed structure is chosen to minimize an integral quadratic objective function subject to the satisfaction of integral quadratic constraint functions. Application of a nonlinear programming algorithm to this mathematically tractable formulation results in an efficient and useful computer aided design tool. Particular attention is paid to computational efficiency and various recommendations are made. Two design examples illustrate the flexibility of the approach and highlight the special insight afforded to the designer. One concerns helicopter longitudinal dynamics and the other the flight dynamics of an aerodynamically unstable aircraft.

Fleming, P.↗