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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Influence of tower shadow on downwind flexible rotors: Field tests and simulations

Abstract As wind turbine rotors become larger, the blades become more flexible, requiring extra stiffness and cost to avoid the risk of tower strike. Wind turbines in a downwind configuration have a reduced risk of tower strike because the rotor thrust acts away from the tower. However, downwind blades pass through the wake of the tower, and the resulting load variation may contribute to blade fatigue. To date, there have been no field tests to quantify this tower shadow effect on unsteady blade moments. The present study reports on the first field testing of a flexible, downwind, coned rotor and compares the experimental data against simulations run in OpenFAST. The tower shadow effect is simulated using the conventional Powles model and a new Eames model (developed herein), which includes the influence of upstream turbulence. Both models reasonably predict the blade root out‐of‐plane bending moment data and the tower shadow dip magnitude when compared to field test data in Region 3. Tower shadow was found to increase the short‐term Damage Equivalent Loads (DELs) by less than 10% compared to other effects (gravity, shear, and turbulence), and the predictions were consistent with experiments. These results indicate that the tower shadow effect can be reasonably modeled with the simpler Powles model and that the tower shadow effect can be small compared to the effect of turbulence. However, long‐term fatigue due to tower shadow should be included in detailed structural analysis and design of the rotor and the tower.

Simpson, Juliet G.↗
DOE OSTI2024

3D printable polymeric lightning strike protection system for fiber reinforced composites

The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.

Kumar, Vipin↗
NASA NTRS1989

Spring-Blade Impact Tester

Record of energy relationships retrieved from compact, portable tester. Spring-blade impact tester developed to support evaluation of tolerance to damage of struts under consideration for use in Space Station. Approach offers potential for determining damage as function of change in relationship between applied and absorbed energies as applied energy successively increased with each impact. Impactor strikes specimen at moment of maximum kinetic energy after spring blades released from cocked position. Concept also provides potential for measuring behavior during impact, and energy relationships retrievable from oscilloscope traces of impact.

Holmes, Alan M.↗
DOE OSTI2022

Field tests of a highly flexible downwind ultralight rotor to mimic a 13-MW turbine rotor

Offshore extreme-scale turbines of 20–25 MW in size may offer reduced energy costs. The technical barriers at these extreme scales include escalating blade masses with increased flexibility as well as high gravity loads and tower-strike issues. These barriers may be addressed with a load-aligning downwind turbine. To investigate this type of design, a field test campaign was conducted with an aeroelastically scaled rotor, termed the Segmented Ultralight Morphing Rotor Demonstrator (SUMR-D). The tests were conducted on the Controls Advanced Research Turbine at the National Renewable Energy Laboratory. The paper gives an overview of the experimental diagnostics, blade design, and results of the field campaign, as well as makes conclusions and recommendations regarding extreme-scale highly flexible downwind rotors.

17 WIND ENERGY↗
NASA NTRS1982

Crystal cleaving machine

A machine is disclosed for cleaving hard crystals. A typical example of which is lithium fluoride, with prcision and uniformity and includes vertical axis positioning control means for an adjustable spring tension guided hammer mechanism employed to strike an anvil. A crystal cleaving shock wave transmitted to a cleaving blade is generated having an angulated cleaving edge in contact with one corner of the crystal. Connection between the anvil and the blade is by means of a pair of vertical shafts held in substantially friction free engagement by two pairs of adjustable linear bearings. An underlying crystal holding fixture with horizontal position control means includes a zero reference stop face for the crystal and opposing spring-loaded clamping and vertical positioning elements which are precisely guided.

Hallberg, F. C.↗
NASA NTRS2014

Detailed Post-Soft Impact Progressive Damage Assessment for Hybrid Structure Jet Engines

Currently, certification of engine designs for resistance to bird strike is reliant on physical tests. Predictive modeling of engine structural damage has mostly been limited to evaluation of individual forward section components, such as fan blades within a fixed frame of reference, to direct impact with a bird. Such models must be extended to include interactions among engine components under operating conditions to evaluate the full extent of engine damage. This paper presents the results of a study aim to develop a methodology for evaluating bird strike damage in advanced propulsion systems incorporating hybrid composite/metal structures. The initial degradation and failure of individual fan blades struck by a bird were investigated. Subsequent damage to other fan blades and engine components due to resultant violent fan assembly vibrations and fragmentation was further evaluated. Various modeling parameters for the bird and engine components were investigated to determine guidelines for accurately capturing initial damage and progressive failure of engine components. Then, a novel hybrid structure modeling approach was investigated and incorporated into the crashworthiness methodology. Such a tool is invaluable to the process of design, development, and certification of future advanced propulsion systems.

bird strike↗
NASA NTRS2003

Spin Testing for Durability Began on a Self-Tuning Impact Damper for Turbomachinery Blades

NASA and Pratt & Whitney will collaborate under a Space Act Agreement to perform spin testing of the impact damper to verify damping effectiveness and durability. Pratt & Whitney will provide the turbine blade and damper hardware for the tests. NASA will provide the facility and perform the tests. Effectiveness and durability will be investigated during and after sustained sweeps of rotor speed through resonance. Tests of a platform wedge damper are also planned to compare its effectiveness with that of the impact damper. Results from baseline tests without dampers will be used to measure damping effectiveness. The self-tuning impact damper combines two damping methods-the tuned mass damper and the impact damper. It consists of a ball located within a cavity in the blade. This ball rolls back and forth on a spherical trough under centrifugal load (tuned mass damper) and can strike the walls of the cavity (impact damper). The ball s rolling natural frequency is proportional to the rotor speed and can be designed to follow an engine-order line (integer multiple of rotor speed). Aerodynamic forcing frequencies typically follow these engineorder lines, and a damper tuned to the engine order will most effectively reduce blade vibrations when the resonant frequency equals the engine-order forcing frequency. This damper has been tested in flat plates and turbine blades in the Dynamic Spin Facility. During testing, a pair of plates or blades rotates in vacuum. Excitation is provided by one of three methods--eddy-current engine-order excitation (ECE), electromechanical shakers, and magnetic bearing excitation. The eddy-current system consists of magnets located circumferentially around the rotor. As a blade passes a magnet, a force is imparted on the blade. The number of magnets used can be varied to change the desired engine order of the excitation. The magnets are remotely raised or lowered to change the magnitude of the force on the blades. The other two methods apply force to the rotating shaft itself at frequencies independent of the rotor speed. During testing, blade vibration is monitored with strain gauges and laser displacement probes.

Duffy, Kirsten↗
NASA NTRS1981

Lightning accommodation systems for wind turbine generator safety

The wind turbine safety program identifies the naturally occurring lightning phenomenon as a hazard with the potential to cause loss of program objectives, injure personnel, damage system instrumentation, structure or support equipment and facilities. Several candidate methods of lightning accommodation for each blade were designed, analyzed, and tested by submitting sample blade sections to simulated lightning. Lightning accommodation systems for composite blades were individually developed. Their effectiveness was evaluated by submitting the systems to simulated lightning strikes. The test data were analyzed and system designs were reviewed on the basis of the analysis. This activity is directed at defining design and procedural constraints, requirements for safety devices and warning methods, special procedures, protective equipment and personnel training.

Bankaitis, H.↗
NASA NTRS2012

Open Circuit Resonant (SansEC) Sensor for Composite Damage Detection and Diagnosis in Aircraft Lightning Environments

Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage and empennage structures, control surfaces and coverings. However, the potential damage from the direct and indirect effects of lightning strikes is of increased concern to aircraft designers and operators. When a lightning strike occurs, the points of attachment and detachment on the aircraft surface must be found by visual inspection, and then assessed for damage by maintenance personnel to ensure continued safe flight operations. In this paper, a new method and system for aircraft in-situ damage detection and diagnosis are presented. The method and system are based on open circuit (SansEC) sensor technology developed at NASA Langley Research Center. SansEC (Sans Electric Connection) sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect damage in composite materials. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. Unique electrical signatures are used for damage detection and diagnosis. NASA LaRC has both experimentally and theoretically demonstrated that SansEC sensors can be effectively used for in-situ composite damage detection.

Wang, Chuantong↗
DOE OSTI2022

Wind Turbine Gust Load Alleviation with Active Flow Control

Large wind turbine rotors are becoming more common in utility-scale wind power, especially for offshore wind plants. However, the trend toward large rotors can be limited by their ability to manage dynamic and extreme loads. To provide a safety margin for the rotor design and avoid catastrophic events such as tower strikes, extreme loads need to be controlled. The objective of this study is to develop and evaluate a feedback control system to alleviate extreme loads and reduce blade deflections under gust events using active flow control devices. We also propose a modification in the turbine controller to achieve further reduction in extreme loads. The extreme load reductions are evaluated under gust wind conditions with direction changes according to the IEC standard. The effects of the gust alleviation controller on turbine performance and fatigue loads are investigated as well. With the deployment of the gust alleviation controller and modified turbine baseline controller, the extreme loads and deflections reduce by up to 23%. The energy captured by the turbine is not affected by the proposed gust alleviation controller. The fatigue loads of various wind turbine components are either reduced or remain unchanged.

17 WIND ENERGY↗
NASA NTRS1985

Fuel containment and damage tolerance in large composite primary aircraft structures. Phase 2: Testing

Technical issues associated with fuel containment and damage tolerance of composite wing structures for transport aircraft were investigated. Material evaluation tests were conducted on two toughened resin composites: Celion/HX1504 and Celion/5245. These consisted of impact, tension, compression, edge delamination, and double cantilever beam tests. Another test series was conducted on graphite/epoxy box beams simulating a wing cover to spar cap joint configuration of a pressurized fuel tank. These tests evaluated the effectiveness of sealing methods with various fastener types and spacings under fatigue loading and with pressurized fuel. Another test series evaluated the ability of the selected coatings, film, and materials to prevent fuel leakage through 32-ply AS4/2220-1 laminates at various impact energy levels. To verify the structural integrity of the technology demonstration article structural details, tests were conducted on blade stiffened panels and sections. Compression tests were performed on undamaged and impacted stiffened AS4/2220-1 panels and smaller element tests to evaluate stiffener pull-off, side load and failsafe properties. Compression tests were also performed on panels subjected to Zone 2 lightning strikes. All of these data were integrated into a demonstration article representing a moderately loaded area of a transport wing. This test combined lightning strike, pressurized fuel, impact, impact repair, fatigue and residual strength.

Sandifer, J. P.↗
NASA NTRS1989

A study of the effects of Rotating Frame Turbulence (RFT) on helicopter flight mechanics

The turbulence actually experienced by a helicopter blade-element significantly differs from the space-fixed free atmospheric turbulence. The turbulence in the rotor disk requires a rotationally sampled description in a rotating frame of reference. It is referred to as the rotating frame turbulence or RFT which exhibits a striking phenomenon. The RFT spectral density versus frequency shows high peak values at 1P,2P, or 3P, frequencies. The energy increase at these peaks is balanced by an energy decrease primarily at the lower-than-1P frequency range. Particularly for low altitude flight regimes of pure helicopters, such as the nap-of-the-earth maneuvers, the conventional space-fixed description of turbulence is not a good approximation, since the turbulence scale length can have values comparable to the rotor radius. Accordingly the flight mechanics characteristics with RFT description are compared with those based on the conventional space-fixed turbulence description. The results demonstrate that the RFT qualitatively and quantitatively affects the prediction of helicopter flight mechanics characteristics in turbulence. Such comparisons should play an important role in the new development of handling qualities specifications for helicopters.

Schrage, D. P.↗
NASA NTRS2016

Pluto and Charon Seen with the New Horizons Spacecraft

After nearly a decade en route, New Horizons flew through the Pluto system in July 2015. The encounter hemisphere of Pluto shows ongoing surface geological activity centered on a vast basin (Sputnik Planum [SP]*) containing a thick layer of volatile ices with a crater retention age no greater than approximately 10 Ma. Surrounding terrains show active glacial flow, apparent transport and rotation of large buoyant water-ice crustal blocks, and pitting, likely by sublimation erosion and/or collapse. Also seen are constructional mounds with central depressions, and ridges with complex bladed textures. Pluto has ancient cratered terrains up to approximately 4 Ga old that are fractured and mantled, and perhaps eroded by glacial processes. Charon does not appear to be currently active, but experienced major tectonism and resurfacing nearly 4 Ga ago. Imaging spectrometer observations of Pluto reveal the encounter hemisphere to be dominated by volatile ices of N2, CO, and CH4, along with non-volatile components that include H2O and tholins. The most volatile of Pluto's ices (N2 and CO) are especially prevalent in the western half of Tombaugh Regio (TR), and the strikingly flat Sputnik Planum basin, which lies a few km below surrounding elevations. The high mobility of N2 and CO ices enables SP's surface to refresh itself sufficiently rapidly that no impact craters are seen there. This likely occurs through a combination of solid state convective overturning and sublimation/ condensation that produces regular patterns of pits and ridges on scales of 102 to 103 m. In many areas, CH4 appears to favor topographically high regions. Its propensity to condense on ridges could play a role in forming the bladed terrain seen in Tartarus Dorsa. H2O can be discerned across much of Cthulhu Regio, and also in a few isolated spots. In many regions, H2O ice is associated with reddish tholin coloration. Pluto's atmosphere was probed with the radio science experiment (REX) and the Alice UV spectrometer, as well as imaging at high phase angles. The surface pressure, due mostly to N2, is approximately 11 microbars. Extensive multiple haze layers are seen in the images. Alice has detected hydrocarbons in addition to CH4 in the atmosphere. Since both are inert, H2O ice and tholin could have similar geological behaviors on Pluto, possibly including aeolian transport or mobilization by volatile ice glaciation. While Pluto's H2O ice is sculpted and at least partially veiled by more volatile ices, Charon's heavily cratered H2O ice is exposed globally. H2O ice spectral bands characteristic of crystalline ice are seen everywhere on the encounter hemisphere. Charon's north polar region is strikingly red, possibly the result of the unique thermal environment of Charon's poles, which become exceptionally cold during the long, dark winters. Extremely cold regions on Charon' could cold trap gases expanding outward from Pluto as ices, and thereby subject them to rapid radiolytic processing. Charon also exhibits a weak NH3 absorption band over most or all of its surface, with small local concentrations. Detailed results of the radio science, small satellite, particles and plasma, and atmosphere investigations are in press.

Pluto↗
NASA NTRS2013

Damage Detection Response Characteristics of Open Circuit Resonant (SansEC) Sensors

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, commercial entities, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into "smart" vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ. NASA Langley Research Center (LaRC) is developing a composite aircraft skin damage detection method and system based on open circuit SansEC (Sans Electric Connection) sensor technology. Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage structures, empennage structures, control surfaces and aircraft skins. SansEC sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect various types of damage in composite materials. The source cause of the in-service damage (lightning strike, impact damage, material fatigue, etc.) to the aircraft composite is not relevant. The sensor will detect damage independent of the cause. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. The unique electrical signatures (amplitude, frequency, bandwidth, and phase) are used for damage detection and diagnosis. An operational system and method would incorporate a SansEC sensor array on select areas of the aircraft exterior surfaces to form a "Smart skin" sensing surface. In this paper a new method and system for aircraft in-situ damage detection and diagnosis is presented. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. NASA LaRC has demonstrated with individual sensors that SansEC sensors can be effectively used for in-situ composite damage detection of delamination, voids, fractures, and rips. Keywords: Damage Detection, Composites, Integrated Vehicle Health Monitoring (IVHM), Aviation Safety, SansEC Sensors

Dudley, Kenneth L.↗
NASA NTRS1998

Modeling of H-46 Tip Strikes

For over thirty years now, the H-46 Sea Knight tandem rotor helicopter has operated successfully from the decks of various U.S. Navy ships. There have been approximately 210 thousand landings and takeoffs at sea and the vast majority have occurred without incident. Only a small percent of the total H-46 landings and takeoffs have been less than fully satisfactory. On certain ships, (e.g. the LHA amphibious assault ship) the combination of winds at 15 deg. or so off of the bow and low rotor r.p.m. are conditions under which, on occasion, the rear rotor blades have been observed to flap uncontrollably. Cases have been reported where the rotor blades have struck the H-46 sync-shaft cover during startup and shutdown while the H-46 is sitting on the deck. One life has been lost, several people injured and the repair costs total of the 110+ incidents has been estimated to exceed $20 million. To date, the root cause of this problem has not been identified.

Zilliac, Greg↗
DOE OSTI2021

An In-Depth Analysis of the Transformation of Tin Foil Anodes during Electrochemical Cycling in Lithium-Ion Batteries

Tin foils have an impressive lithium-storage capacity more than triple that of graphite anodes, and their adoption could facilitate a drastic improvement in battery energy density. However, implementation of a dense foil electrode architecture represents a significant departure from the standard blade-cast geometry with a distinct electrochemical environment, and this has led to confusion with regards to the first cycle efficiency of the system. In this work, we investigate the unique behavior of a tin active material in a foil architecture to understand its performance as an anode. We find shallow cycling of the foil results in an irreversible formation (< 40%) due to diffusional trapping, but intermediate and complete utilization allows for a remarkably reversible formation reaction (> 90%). This striking nonlinearity stems from an in situ transformation from bulk metal to porous electrode that occurs during formation cycles and defines electrode-level lithium-transport on subsequent cycles. As a result, an alternative cycling procedure for assessing the stability of foils is proposed to account for this chemomechanical effect.

25 ENERGY STORAGE↗
DOE OSTI2023

Aerodynamic Rotor Design for a 25 MW Offshore Downwind Turbine

Continuously increasing offshore wind turbine scales require rotor designs that maximize power and performance. Downwind rotors offer advantages in lower mass due to reduced potential for tower strike, and is especially true at large scales, e.g., for a 25 MW turbine. In this study, three 25 MW downwind rotors, each with different prescribed lift coefficient distributions were designed (chord, geometry, and twist) and compared to maximize power production at unprecedented scales and Reynolds numbers, including a new approach to optimize rotor tilt and coning based on aeroelastic effects. To achieve this objective the design process was focused on achieving high power coefficients, while maximizing swept area and minimizing blade mass. Maximizing swept area was achieved by prescribing pre-cone and shaft tilt angles to ensure the aeroelastic orientation when the blades point upwards was nearly vertical at nearly rated conditions. Maximizing the power coefficient was achieved by prescribing axial induction factor and lift coefficient distributions which were then used as inputs for an inverse rotor design tool. The resulting rotors were then simulated to compare performance and subsequently optimized for minimum rotor mass. To achieve these goals, a high Reynolds number design space was developed using computational predictions as well as new empirical correlations for flatback airfoil drag and maximum lift. Within this design space, three rotors of small, medium and large chords were considered for clean airfoil conditions (effects of premature transition were also considered but did not significantly modify the design space). The results indicated that the medium chord design provided the best performance, producing the highest power in Region 2 from simulations while resulting in the lowest rotor mass, both of which support minimum LCOE. The methodology developed herein can be used for the design of other extreme-scale (upwind and downwind) turbines.

downwind rotors↗
NASA NTRS1979

X-ray photoelectron spectroscopy study of nickel and nickel-base alloy surface alterations in simulated hot corrosion conditions with emphasis on eventual application to turbine blade corrosion

Research on the high temperature oxidation and Na2SO4 induced hot corrosion of some nickel base superalloys was accomplished by using ESCA to determine the surface composition of the oxidized or corroded samples. Oxidation was carried out at 900 or 1000 C in slowly flowing O2 for samples of B-1900, NASA-TRW VIA, 713C, and IN-738. Oxidation times ranged from 0.5 to 100 hr. Hot corrosion of B-1900 was induced applying a coating of Na2SO4 to peroxidized samples, the heating to 900 C in slowly flowing O2. For oxidized samples, the predominant type of scale formed by each superalloy was determined, and a marked surface enrichment of Ti was found in each case. For corroded samples, the transfer of significant amounts of material from the oxide layer to the surface of the salt layer was observed to occur long before the onset of accelerating weight-gain. Changes in surface composition were observed to coincide with the beginning of accelerating corrosion, the most striking of which was a tenfold decrease in the sulfur to sodium ration and an increase in the Cr(VI) ratio.

Mateescu, G. D.↗